Vehicle Gap Measurement Module with Adaptive Light Brightness
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Solution Overview
Problem
Conventional gap/height difference measurement modules for vehicles face challenges in accurately measuring panels with different colors or chrome molding due to scattered light of varying brightness, leading to low measurement accuracy and reliability.
Innovation Solution
A gap/height difference measurement module equipped with first and second sensors, each mounted with filters, that detect and adjust to light of different brightness from diagonally mounted light sources, allowing for accurate extraction of straight-line elements from cross sections and precise measurement of hemming edges, regardless of panel color or chrome molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If light sources emit light of the same brightness onto panels, then measurement is simple, but measurement accuracy deteriorates when panels have different colors or chrome molding due to light scattering
Solution Approach 1:
The patent applies local quality by assigning different brightness levels to different light sources based on the specific panel being measured. Each light source is independently controlled to emit light at an optimal brightness level for its target panel, allowing accurate detection despite variations in panel color and material properties.
Solution Approach 2:
The patent changes the brightness parameter of light sources dynamically. The control unit adjusts the brightness of each light source according to the panel's optical properties, transforming a static lighting system into a dynamic one that adapts to different measurement conditions, thereby maintaining high measurement accuracy across diverse panel types.
2Measurement precision
If light sources emit light of different brightness to compensate for panel color variations, then measurement accuracy improves, but measurement reliability deteriorates due to scattered light detection difficulties
Solution Approach 1:
The patent implements feedback through the control unit that receives detection results from sensors and adjusts light source brightness accordingly. This closed-loop control ensures that the light brightness is continuously optimized based on actual detection conditions, improving both accuracy and reliability by adapting to real-time variations in panel properties and light scattering patterns.
Solution Approach 2:
The control unit acts as an intermediary between the light sources and sensors, coordinating their operation to achieve optimal measurement conditions. It manages the complex interaction between variable brightness light sources and panels with different optical properties, ensuring reliable detection by balancing light emission with sensor detection capabilities.
3Measurement precision
If manual gauge check and naked-eye inspection are used, then device complexity is low, but measurement accuracy and quality control uniformity deteriorate due to worker dependency
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated optical measurement system. Sensors detect light patterns to determine gap and height differences, substituting human eyes and manual gauges with electronic detection devices that provide consistent, objective measurements independent of worker skill or fatigue.
Solution Approach 2:
The measurement system performs self-adjustment through the control unit that automatically regulates light source brightness based on panel characteristics. This self-service capability eliminates the need for manual calibration or adjustment by operators, maintaining consistent measurement quality while reducing device operational complexity.
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 enhances measurement accuracy and reliability by enabling sensors to detect and adjust to varying light brightness, ensuring accurate gap/height difference measurements across diverse panel types, improving uniformity and applicability to various vehicle models.
Implementation Method 1
when light emitted from each light source is irradiated between the panels, the sensors detect straight-line elements from cross sections formed by light through the panels
Implementation Method 2
first and second filters that are respectively mounted to the first and second sensors so as to allow the first and second sensors to each extract straight-line elements from cross sections formed as the lights emitted from the first and second light are irradiated onto the panels
Data Source
AI summary
A gap and height difference measurement module may include a mounting frame with a flange mounted on a first end thereof and a connecting frame mounted on a second end of the mounting frame, first and second housings mounted on both sides of the connecting frame respectively, a first light source mounted on a lower end of the first housing and emitting light onto the panels, a second light source mounted on a lower end of the second housing and emitting light onto the panels, first and second sensors respectively mounted on front ends of the first and second housings, and first and second filters that are respectively mounted to the first and second sensors so as to allow the first and second sensors to each extract straight-line elements from cross sections formed as the lights emitted from the first and second light are irradiated onto the panels.