Sheet Metal Deep-Drawn Housing for Camera Alignment
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Solution Overview
Problem
The existing camera systems for driver assistance in vehicles are expensive and complex to produce, particularly in large quantities, due to the use of die-cast parts which are required for correct alignment and EMC compliance, leading to high material costs and manufacturing complexity.
Innovation Solution
A camera system with a housing composed of two sheet metal deep-drawn parts, eliminating the need for die-cast components, which allows for cost-effective production, flexible design, and improved EMC behavior, while using internal reference surfaces for precise alignment of the camera module and optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die-cast parts are used for housing to ensure correct alignment and EMC compliance, then alignment precision and EMC behavior are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The housing is divided into multiple sheet metal parts that are assembled together using standardized fastening elements, replacing the monolithic die-cast structure. This segmentation allows each part to be manufactured independently using cost-effective deep-drawing processes while maintaining overall alignment precision through modular design and standardized connection interfaces.
Solution Approach 2:
The material and manufacturing process parameters are changed from die-cast metal to sheet metal with deep-drawing process. This parameter change reduces manufacturing complexity and cost while maintaining structural integrity and alignment capabilities through optimized sheet metal forming and assembly techniques.
2Manufacturing precision
If die-cast parts are used for housing to ensure correct alignment and EMC compliance, then alignment precision and EMC behavior are improved, but manufacturing cost increases
Solution Approach 1:
The housing is segmented into multiple sheet metal components that can be manufactured using high-volume, cost-effective deep-drawing processes. This segmentation eliminates the need for expensive die-casting operations while maintaining alignment precision through modular assembly with standardized fastening elements.
Solution Approach 2:
The patent employs standardized fastening elements and sheet metal parts that are cost-effective and suitable for high-volume production. These components replace expensive die-cast parts while achieving the same functional requirements through economical manufacturing methods.
3Object-affected harmful factors
If the housing is made completely closed for EMC compliance, then EMC behavior is improved, but manufacturing complexity increases
Solution Approach 1:
The closed housing structure is achieved through assembly of multiple sheet metal parts with standardized fastening elements, creating a complete enclosure for EMC compliance. This segmented approach allows each part to be manufactured separately using simple deep-drawing processes, reducing overall manufacturing complexity compared to a single-piece die-cast enclosure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces production costs, weight, and complexity, while ensuring effective electromagnetic compatibility (EMC) and thermal conductivity, allowing for a more affordable and efficient camera system with precise alignment and flexible design.
Implementation Method 1
the housing is also made of a conductive material and is as completely closed as possible. As a result of this requirement, the die-cast part must also be designed accordingly, and the overall cost of materials is high
Implementation Method 2
In particular, such a housing also has advantageous thermal conductivity properties
Data Source
Figure 1
AI summary
The invention relates to a camera system (2) of a driver assistance system, comprising a camera module (14) having optics (14b), a housing (4) comprising a first and a second housing part (6, 8) which are each made of sheet metal, and a circuit board (26) arranged in the housing (4), wherein at least the first housing part (6) is a deep-drawn part.