Vehicle Sensor Assembly Jig Tolerance Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for installing vehicle sensors lack efficiency in maintaining precise positional alignment and orientation, leading to potential blind spots and misalignments that can hinder autonomous or semi-autonomous vehicle operations.
Innovation Solution
A method involving the use of tolerance compensators and a jig to fix sensor brackets to a vehicle, allowing for precise adjustment and maintenance of sensor positions relative to the vehicle and each other, eliminating the need for iterative measurement and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional sensor installation methods are used, then installation process is simple, but sensor positional alignment precision deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-configuring the jig with precise datum features and tolerance compensators before sensor installation. The jig is prepared with pre-drilled holes, pre-positioned tolerance compensators, and precise mechanical features that establish correct sensor positions in advance. This preliminary setup eliminates the need for iterative measurement and adjustment during actual sensor installation, thereby improving positional alignment precision while keeping the installation process manageable.
Solution Approach 2:
The patent uses the jig as an intermediary device between the sensor brackets and the vehicle body. The jig acts as a mediator that transfers precise positional information from its pre-configured datums to the sensor brackets through the tolerance compensators. This intermediary mechanism ensures accurate sensor positioning without requiring complex direct measurement and adjustment procedures between the sensors and vehicle body, resolving the contradiction between precision and complexity.
2Manufacturing precision
If iterative measurement and adjustment methods are used, then sensor positions can be adjusted, but installation time increases
Solution Approach 1:
The jig is pre-configured with tolerance compensators and precise mechanical features before sensor installation begins. The tolerance compensators are pre-adjusted to the correct dimensions, and the jig's datum features are pre-established. This preliminary preparation eliminates the need for iterative measurement and adjustment during sensor installation, achieving high position accuracy in a single operation and significantly reducing installation time.
Solution Approach 2:
The patent replaces the iterative mechanical measurement and adjustment system with a pre-configured mechanical jig system. Instead of repeatedly measuring and adjusting sensor positions using traditional tools, the jig provides mechanical constraints and tolerance compensation that automatically establish correct sensor positions. This substitution of the adjustment mechanism with a pre-configured positioning system eliminates time-consuming iterative processes while maintaining high accuracy.
3Reliability
If precise sensor positioning is achieved through traditional methods, then alignment is maintained, but blind spots may occur due to misalignment
Solution Approach 1:
The jig serves as an intermediary that ensures reliable sensor alignment by transferring precise positional information from its pre-configured datums to the sensor brackets. The tolerance compensators within the jig actively compensate for dimensional variations in the vehicle body and sensor brackets, maintaining consistent sensor positions that prevent misalignment-related blind spots. This intermediary mechanism reliably maintains sensor alignment across different vehicle units, eliminating the harmful effect of blind spots.
Solution Approach 2:
The tolerance compensators in the jig allow for parameter changes in the form of adjustable dimensions to compensate for variations in vehicle body and bracket manufacturing tolerances. By adjusting the compensator dimensions, the system maintains the correct sensor positions despite variations in other parameters, ensuring reliable alignment and preventing blind spots caused by misalignment.
Data Source
AI summary
A method for installing sensors to a vehicle includes fixing a plurality of tolerance compensators to the vehicle. The method includes fixing a plurality of sensor brackets to a jig. The method includes fixing the jig to a vehicle. The method includes, after fixing the sensor brackets to the jig and the jig to the vehicle, fixing the sensor brackets to the vehicle by connecting the tolerance compensators to the sensor brackets and adjusting dimensions of the tolerance compensators to maintain positions of the sensor brackets relative to the vehicle and each other, the positions defined by the jig.