Thermal Image Tracking for Autonomous Vehicle Connector Mating

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Solution Overview

Problem

Existing docking operations for autonomous 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 complexity and certification difficulties, making them difficult to implement in drones and spacecraft.

Innovation Solution

A thermal imaging sensor and vision processor system that generates thermal images, performs thresholding, and identifies regions of interest to estimate range and position, enabling autonomous connector mating without increasing processing resources or sensors.

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 automation extent and certification ease deteriorate

Engineering Contradiction:

Improveoperational flexibilityVSAvoidautomation extent

Core Design Contradiction:

Ease of operationVSExtent of automation

Solution Approach 1:

The patent replaces human operators with an autonomous vision-based system that uses thermal imaging sensors and computer vision algorithms to perform docking operations. The system processes thermal image data to identify target vehicles, estimate range, and guide connector mating autonomously, eliminating the need for human judgment while achieving high success rates in complex maneuvers like air-to-air refueling and spacecraft docking

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-guidance by autonomously processing its own sensor data to make docking decisions. The vision processor independently analyzes thermal images, identifies regions of interest, estimates range to target vehicles, and controls connector positioning without external human intervention, enabling the system to serve itself in complex autonomous operations

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If human operators guide docking operations, then adaptability to complex situations is improved, but productivity and repeatability deteriorate

Engineering Contradiction:

Improveadaptability to complex situationsVSAvoiddocking speed and repeatability

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system maintains continuous autonomous operation by constantly processing thermal image data to track target vehicles and adjust connector positioning in real-time. This continuous feedback loop enables high-speed docking operations with consistent repeatability, as the system continuously adapts to changing relative positions and environmental conditions without human intervention

Inventive Principle:

Principle #20Continuity of useful action

3Measurement precision

If stereoscopic vision systems are used to aid human operators, then measurement precision is improved, but device complexity increases

Engineering Contradiction:

Improverange estimation accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent changes the operational parameter from visible light to thermal infrared wavelengths. By using thermal imaging sensors that detect heat signatures, the system achieves reliable target detection and range estimation without requiring complex stereoscopic vision systems. The thermal imagery provides sufficient measurement precision for docking operations while significantly reducing system complexity compared to multi-camera visible light systems

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts and utilizes only the thermal radiation information from the environment, eliminating the need for complex visible light imaging systems. By focusing exclusively on thermal signatures of target vehicles, the system achieves accurate target identification and range estimation with simpler hardware, removing unnecessary complexity associated with stereoscopic vision and visible light processing

Inventive Principle:

Principle #2Taking out (Extraction)

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

Provides an all-optical, passive solution for connector mating with high confidence and reliability, reducing costs and improving maneuver predictability and repeatability compared to human-operated systems.

Implementation Method 1

a thermal imaging sensor configured to generate thermal image data depicting at least a portion of a vehicle

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS20250329043A1Thermal 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 and a vision processor. The thermal imaging sensor is configured to generate thermal image data depicting at least a portion of a vehicle. The vision processor is configured to perform thresholding on the thermal image data to generate a thresholded thermal image including pixels having intensity values that satisfy a threshold. The vision processor is also configured to identify one or more regions of interest in the thresholded thermal image based on pixel characteristics associated with the one or more regions of interest. The vision processor is further configured to estimate a range between the device and the vehicle based on the one or more regions of interest.