Vehicle Surroundings Sensor Calibration During Production-Line Motion
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Solution Overview
Problem
Calibration of vehicle surroundings sensors in a production line is time-consuming and complex, requiring human intervention and additional calibration stations, which disrupts the production process and reduces efficiency.
Innovation Solution
A system comprising a stationary calibration server and onboard vehicle surroundings sensor modules, utilizing wireless communication and stationary sensors to capture and analyze sensor data from reference objects, enabling autonomous calibration during vehicle movement through a designated area of the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vehicle surroundings sensors are calibrated in a stationary calibration station, then calibration accuracy is improved, but production time is increased and throughput is reduced
Solution Approach 1:
The calibration system transitions from a stationary setup to a dynamic one where the calibration target moves with the vehicle along the production line. The target is attached to the vehicle and moves synchronously, allowing calibration to occur during vehicle movement rather than requiring the vehicle to stop, thus maintaining calibration accuracy while improving throughput.
Solution Approach 2:
A calibration target serves as an intermediary element between the vehicle's sensors and the production line infrastructure. This target carries calibration patterns and moves with the vehicle, enabling continuous calibration data acquisition without interrupting the production flow.
2Device complexity
If multiple sensors are calibrated in the same calibration station, then device complexity is reduced, but calibration time is increased
Solution Approach 1:
The calibration process becomes continuous rather than sequential. Multiple sensors can be calibrated simultaneously as the vehicle moves along the production line, with the calibration target continuously providing reference patterns for all sensors. This eliminates the need for sequential calibration of each sensor and reduces total calibration time.
Solution Approach 2:
The calibration target serves multiple functions: it provides calibration patterns for different sensor types (cameras, radar, lidar), supports multiple calibration operations simultaneously, and can be used throughout the production line. This multi-functional approach allows comprehensive sensor calibration without requiring separate specialized stations for each sensor type.
3Stability of the object's composition
If the vehicle is moved to a calibration station and parked, then calibration stability is improved, but production efficiency is reduced
Solution Approach 1:
The system accepts and compensates for dynamic conditions during calibration. The calibration target moves synchronously with the vehicle, and the system is designed to process calibration data from moving conditions. This eliminates the need to park the vehicle while maintaining sufficient calibration stability through synchronous movement and appropriate data processing.
Solution Approach 2:
The traditional mechanical approach of stopping the vehicle for calibration is replaced with an optical/information-based approach. Calibration patterns are projected or displayed on a moving target, and image processing algorithms compensate for motion, replacing the need for mechanical stabilization through vehicle parking.
4Reliability
If pivotable calibration devices are permanently installed, then calibration capability is improved, but mechanical wear and positioning precision requirements increase
Solution Approach 1:
The mechanical pivotable calibration devices are replaced with a non-mechanical approach. Instead of moving mechanical components to position calibration targets, the system uses a calibration target attached to the vehicle that moves naturally with the production line. This eliminates mechanical wear and reduces positioning precision requirements while maintaining calibration capability.
Solution Approach 2:
The calibration target serves itself by being attached to the vehicle and moving synchronously with it. The target automatically positions itself relative to the vehicle's sensors during normal vehicle movement, eliminating the need for separate positioning mechanisms and reducing system complexity.
Data Source
AI summary
A vehicle surroundings sensor module on board a vehicle is connected to a one vehicle surroundings sensor and is configured, in a calibration mode, to progressively transmit vehicle surroundings sensor data captured by the vehicle surroundings sensor via a wireless communication interface to a calibration server when the vehicle is moved through a calibration area, which comprises at least one section of a production line, at least one stationary surroundings sensor, which is configured to capture surroundings sensor data of a set of reference objects in the calibration area and to transmit these data to the calibration server, and at least one stationary position sensor, which is configured, during the movement of the vehicle through the calibration area, to progressively capture a position of the vehicle and transmit vehicle position data to the calibration server. The calibration server is configured to associate captured vehicle position data with the received vehicle surroundings sensor data, which capture the set of reference objects, and, using associated surroundings sensor data of the set of reference objects, to ascertain calibration parameters for the vehicle surroundings sensor and transmit these parameters to the vehicle surroundings sensor module.