Thermal Drogue Tracking for Autonomous Vehicle Connector Mating

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Solution Overview

Problem

Existing docking operations for vehicles, such as air-to-air refueling and spacecraft docking, rely heavily on human judgment and are challenging to extend to autonomous systems due to the complexity and precision required, making them difficult to certify and increasing costs.

Innovation Solution

A thermal imaging sensor and vision processor system is used to generate and process thermal images to detect multiple candidate locations of a drogue, providing a tracked position for connector mating, thereby reducing reliance on human operators and enhancing system reliability and certification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If human operators guide complex docking operations, then operational flexibility and judgment are improved, but cost and training requirements increase

Engineering Contradiction:

Improveoperational flexibilityVSAvoidtraining requirements

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces human operators with an autonomous vision-based system that uses thermal imaging sensors and computer vision algorithms to detect, track, and guide connector mating operations. This substitution eliminates the need for human judgment while achieving autonomous operation in GPS-denied environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-guidance by processing its own sensor data through computer vision algorithms to automatically determine connector positions and guide mating operations without external human intervention or reliance on GPS/INS systems.

Inventive Principle:

Principle #25Self-service

2Extent of automation

If artificial intelligence-based solutions are used for autonomous docking, then automation is improved, but certification difficulty increases

Engineering Contradiction:

Improveautonomous operationVSAvoidcertification difficulty

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The patent replaces complex AI-based computer vision systems with a simplified thermal image processing approach that uses traditional image processing algorithms to detect thermal signatures of connectors. This substitution maintains automation while improving certifiability through deterministic, well-understood processing methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system changes the detection parameter from visual features (used in AI-based solutions) to thermal features, exploiting the thermal contrast between connectors and surrounding structures. This parameter change enables reliable detection with simpler algorithms that are easier to certify.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If thermal image processing is used to detect connector locations, then measurement reliability is improved, but processing complexity increases

Engineering Contradiction:

Improveconnector location detectionVSAvoidprocessing complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies local quality by focusing thermal image processing on specific regions of interest where connectors are expected to be located. The system processes only relevant thermal signatures rather than entire images, reducing computational complexity while maintaining detection precision.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system changes the detection approach from analyzing complex visual features to detecting thermal contrast patterns. This parameter change simplifies the processing algorithm while improving measurement reliability by exploiting the distinct thermal signatures of connectors against their background.

Inventive Principle:

Principle #35Parameter changes

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 system provides a cost-effective, reliable, and certifiable solution for autonomous connector mating, improving efficiency and reducing training costs by using all-optical, passive tracking methods, even in environments where GPS or INS systems are inoperable.

Implementation Method 1

a thermal imaging sensor configured to generate a thermal image depicting a drogue attached to a vehicle

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS20250329051A1Thermal image-based tracking to mate connectors of vehicles

Publication Date: 2025.10.23 THE BOEING CO

AI summary

A device includes a thermal imaging sensor configured to generate a thermal image depicting a drogue attached to a vehicle. The device includes a vision processor coupled to the thermal imaging sensor. The vision processor is configured to process the thermal image to obtain multiple candidate locations of the drogue in the thermal image and one or more scores associated with each of the candidate locations. The device also includes a second processor configured to process the candidate locations and the one or more scores associated with each of the candidate locations to generate a tracked position of the drogue.