Windshield HUD Calibration Using Camera Arrays for Image Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing head-up display (HUD) systems in vehicles face challenges in accurately projecting images onto windshields due to manufacturing tolerances, resulting in misalignment and distortion, which requires costly robotic systems for calibration and is impractical for in-service adjustments.
Innovation Solution
A method and system that use a camera array mounted on a fixture attached to vehicle components to capture images of physical and virtual targets, determining misalignments and offsets to adjust the HUD image projection without precise robotic calibration, allowing for on-site adjustments by displaying a virtual target and using distortion compensation maps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If robotic systems are used for HUD calibration, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses a camera array to capture images of physical targets and virtual HUD targets, creating a digital representation of the alignment state. This copying approach replaces complex robotic positioning systems with simpler optical measurement, achieving precise alignment verification through image processing rather than mechanical adjustment
Solution Approach 2:
The patent replaces mechanical robotic calibration systems with an optical measurement system using cameras and image processing. The distortion compensation map and coordinate transformation algorithms substitute for mechanical adjustment mechanisms, enabling precision alignment through computational methods rather than physical robotic manipulation
2Manufacturing precision
If robotic calibration systems are used, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent pre-calculates distortion compensation maps and establishes coordinate transformation relationships between camera arrays and HUD systems during the design phase. These pre-computed parameters are stored and directly applied during production, eliminating the need for time-consuming real-time robotic calibration and enabling rapid alignment verification
Solution Approach 2:
By using camera arrays to capture and process images of alignment targets, the system creates digital copies of the physical alignment state. This allows for rapid automated image processing and alignment verification without the time-consuming mechanical adjustments required by robotic systems, significantly speeding up the calibration process
3Manufacturing precision
If precise robotic calibration is used, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent uses camera arrays to capture images of physical and virtual targets, creating digital representations that are processed through automated algorithms. This copying and computational approach replaces complex robotic calibration procedures with simpler optical measurement and image processing, making the manufacturing process more accessible and easier to implement
Solution Approach 2:
The patent replaces complex mechanical robotic calibration systems with optical measurement and computational algorithms. The distortion compensation maps and coordinate transformations provide a mathematical framework that simplifies the calibration process, eliminating the need for expensive and complex robotic hardware while achieving comparable or superior precision
4Ease of manufacture
If manufacturing tolerances are relaxed, then ease of manufacture is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent employs camera arrays to capture images of alignment targets and compares actual positions with expected positions, generating feedback information. This feedback is used to calculate distortion compensation maps and adjust alignment parameters, enabling the system to compensate for manufacturing tolerances and achieve precise alignment even with relaxed assembly specifications
Solution Approach 2:
The patent uses distortion compensation maps that modify coordinate parameters to correct for manufacturing variations. By changing the mathematical parameters used to map HUD coordinates to windshield coordinates, the system can compensate for tolerance stack-up and achieve accurate image placement without requiring tight manufacturing tolerances
Data Source
AI summary
A method includes placing a physical target on a windshield of a vehicle, mounting a fixture inside the vehicle to position a camera array on the fixture within a line of sight of a passenger, capturing images of the physical target using the camera array, and determining a difference between actual and target locations of the physical target in each image. In addition, the method includes controlling the HUD to display a virtual target on the windshield, capturing images of the virtual target using the camera array, and determining a target location of the virtual target in each image based on the difference. Further, the method includes determining an offset between an actual location of the virtual target in each image and the target location of the virtual target in each image, and adjusting the location of an image projected onto the windshield by the HUD based on the offset.