Vehicle Vision Sensor Actuator Alignment

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Solution Overview

Problem

Current automotive camera manufacturing processes for focus alignment are complex and expensive, requiring specialized equipment for precise alignment of the image sensor with the lens, leading to increased costs and potential misalignment issues due to aging components.

Innovation Solution

Incorporation of an image sensor actuator that allows for manual alignment of the image sensor with the lens focal plane without the need for expensive alignment machines, enabling alignment at the camera manufacturing facility or during vehicle assembly, and compensating for misalignments caused by aging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If specialized alignment equipment is used for precise focus alignment, then manufacturing precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvefocus alignment precisionVSAvoidalignment equipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The vision sensor performs self-alignment by capturing test images at different focus positions and automatically determining the optimal focus setting through image analysis, eliminating the need for specialized external alignment equipment

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces mechanical alignment equipment with an automated software-based focus determination system that uses image capture and processing to achieve precise focus alignment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual alignment is performed without specialized equipment, then device complexity is reduced, but manufacturing precision deteriorates

Engineering Contradiction:

Improvealignment equipmentVSAvoidfocus alignment precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical alignment equipment with an automated software-based focus determination system that uses image capture and processing to achieve precise focus alignment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system captures test images at different focus positions, analyzes the images to determine which position provides the sharpest focus, and uses this feedback to automatically set the optimal focus alignment

Inventive Principle:

Principle #23Feedback

3Ease of manufacture

If rigid mounting is used for image sensor, then ease of manufacture is improved, but reliability deteriorates due to aging-induced misalignment

Engineering Contradiction:

Improvemounting processVSAvoidfocus alignment stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces rigid fixed mounting with an adjustable mounting system that allows the image sensor to be repositioned along the optical axis to compensate for aging-induced misalignment

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system provides adjustability in the position parameter of the image sensor relative to the lens, allowing compensation for changes in alignment that occur over time due to aging

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250332996A1Vehicle vision system

Publication Date: 2025.10.30 FORD GLOBAL TECH LLC

AI summary

A vision sensor includes a housing, a lens, a circuit board, an image sensor, and an actuator. The housing defines an internal cavity and an orifice providing access to the internal cavity. The lens is disposed within the orifice, is secured to the housing such that a position of the lens is affixed relative to the housing, and defines a focal plane within the internal cavity. The circuit board is disposed within the internal cavity and is secured to the housing such that a position of the circuit board is affixed relative to the housing and relative to the lens. The image sensor is disposed within the internal cavity and is connected to the circuit board. The actuator is configured to adjust a position of the image sensor relative to the circuit board to align the image sensor with the focal plane.