Stereo Camera Roll Angle Alignment Using Bare Die Reference Edges
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Solution Overview
Problem
Current stereo camera systems require costly and labor-intensive active adjustments to align camera modules precisely with respect to their roll angle, due to extensive tolerance chains within the system and its components, which complicates the manufacturing process and reduces accuracy in object distance calculations.
Innovation Solution
The use of unpackaged image recording elements (bare die image chips) and defined outer reference edges on mounting plates allows for precise alignment of camera modules without active roll angle adjustment, reducing the tolerance chain to only the roll angle tolerance between the image recording elements and the support device, by aligning pixel rows and columns parallel to the reference edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active adjustment is used to align camera modules, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes the active adjustment mechanism entirely from the system. Instead of using adjustable mounts or alignment mechanisms, the camera modules are designed with fixed mounting structures that achieve precise alignment through careful mechanical design and tolerance control during assembly.
Solution Approach 2:
The alignment is pre-established through the mechanical design of the mounting structure and housing. Reference edges and alignment features are built into the components during manufacturing, so that when the camera modules are installed, they are automatically aligned to the correct roll angle without requiring subsequent adjustment.
2Manufacturing precision
If active adjustment is used to align camera modules, then manufacturing precision is improved, but manufacturing time increases
Solution Approach 1:
The time-consuming active adjustment process is completely removed from the manufacturing workflow. The fixed mounting design allows camera modules to be installed and aligned in a single assembly operation, eliminating the need for iterative adjustment and verification steps.
Solution Approach 2:
All alignment considerations are resolved during the design and manufacturing of the mounting components. Reference edges, alignment slots, and mechanical stops are pre-configured to ensure correct roll angle alignment, so that assembly workers simply need to install the modules without performing any alignment operations.
3Manufacturing precision
If tolerance chains are reduced, then manufacturing precision is improved, but ease of manufacture worsens
Solution Approach 1:
The alignment function is segmented into separate reference features on different components. The housing has reference edges, the mounting plate has alignment features, and the camera module has corresponding interface features. This segmentation allows each component to be manufactured independently with standard tolerances while achieving precise overall alignment through the reference feature interfaces.
Solution Approach 2:
Reference edges and alignment features act as intermediary elements between components. Instead of requiring direct precision between mating surfaces, these reference features serve as mediators that translate standard manufacturing tolerances into precise roll angle alignment. The reference edges provide a common reference framework that simplifies the assembly process.
Data Source
AI summary
The invention relates to a method for aligning at least two image recording elements of two camera modules of a stereo camera system, in particular with respect to their roll angle relative to one another, as well as to a stereo camera system whose camera modules or image recording elements are aligned in accordance with such method.