Vehicle Sensor Calibration Using Rigid Modular Mounts
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Solution Overview
Problem
Existing vehicle systems face challenges in accurately calibrating sensors, particularly stereo camera pairs, when in motion due to vibration and environmental factors, leading to instability and reduced accuracy in 3D imaging data, and traditional calibration methods require offline processes that are inconvenient and limited by vehicle design.
Innovation Solution
A system with detached sensing modules mounted on rigid plates, each with a calibration device, continuously calibrates sensors by detecting a calibration target within their field of view, using data from cameras or laser range finders to determine relative positions and update calibration parameters in real-time, allowing for flexible placement and accurate calibration even with wide-baseline stereo pairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensors are mounted on a rigid placement bar to maintain fixed relative positions, then manufacturing precision and calibration accuracy are improved, but device complexity and flexibility of sensor placement are worsened
Solution Approach 1:
The system divides the sensor mounting structure into separate modular sensing modules, each with its own mounting plate, rather than using a single rigid placement bar. This segmentation allows each module to be independently calibrated and positioned, maintaining calibration accuracy while reducing structural complexity and increasing placement flexibility.
Solution Approach 2:
The patent replaces the mechanical rigid placement bar system with an optical/electronic calibration system using cameras and laser range finders. Instead of relying purely on mechanical rigidity to maintain sensor positions, the system uses continuous optical measurement and digital calibration to achieve and maintain precise relative positioning.
2Manufacturing precision
If traditional offline calibration methods are used, then manufacturing precision is improved, but productivity and ease of operation are worsened due to vehicle downtime and limited flexibility
Solution Approach 1:
The calibration system transitions from a static offline process to a dynamic continuous process. Sensors are calibrated while the vehicle is in motion through continuous measurement of a calibration target, enabling calibration to occur during normal operation rather than requiring vehicle downtime.
Solution Approach 2:
The system performs calibration continuously during vehicle operation rather than in discrete offline sessions. The sensing modules continuously track the calibration target and update relative position data in real-time, maintaining calibration accuracy throughout the vehicle's operational life without interrupting service.
3Manufacturing precision
If sensors are placed close together to improve manufacturing precision, then manufacturing precision is improved, but adaptability and field of view are worsened
Solution Approach 1:
The system uses continuous feedback from cameras and laser range finders to measure and compensate for position variations between sensors. This feedback mechanism allows sensors to be placed at greater distances apart while maintaining effective calibration accuracy, thereby expanding the field of view and adaptability of the system.
Data Source
AI summary
Embodiments provide a hardware-based mechanism to continuously calibrate a set of sensors on a vehicle while the vehicle is in motion or in use. Specifically, each sensor is mounted on a respective rigid mounting device placed on the vehicle. A secondary sensing device for calibration is also rigidly mounted on the mounting device such that the relative position between the secondary device and the camera sensor can remain unchanged. The secondary sensing devices can then be used to detect a relative distance and/or position of the same calibration target. The sensed data is then used to determine, via stereo triangulation, the relative positions of the two secondary sensing devices, which in turn indicates the relative positions of the sensors.