Sensor Mounting Device for Sensor Testing

Abstract

Disclosed are a sensor mounting apparatus and associated method, e.g. for use in testing of a vehicle sensor in an anechoic chamber. The apparatus features a sensor mounting device for mounting the sensor and a vehicle part mounting device comprised of first, second and third frames. Each frame is movable in a different direction relative to the sensor and each other frame, e.g. either: adjustable forward and back, left and right, up and down, and/or via roll, yaw and pitch. The outermost third frame further includes an attachment means for holding a vehicle part (e.g. a vehicle fascia/bumper) in place and provision for further adjustment of the part relative to the sensor in use, e.g. via a pivot mounting enabling yaw movement.

Claims

1. A sensor mounting apparatus for testing comprising: a sensor mounting device for mounting a sensor; and a vehicle part mounting device for mounting a vehicle part, the vehicle part mounting device comprises a plurality of frames, each frame movable in a different direction relative to the sensor and each other frame.

2. The sensor mounting apparatus of claim 1, wherein the moveable direction of each frame comprises at least one of: forward and back, left and right, up and down, roll, or yaw and pitch.

3. The sensor mounting apparatus of claim 1, wherein the plurality of frames comprises at least three frames arranged to fit successively inside each other from a largest outermost frame to a smallest innermost frame, wherein the largest outermost frame comprises or is coupled to a vehicle part mounting device with attachment features for attaching to a vehicle part.

4. The sensor mounting apparatus of claim 3, wherein the vehicle part mounting device comprises at least one additional position adjustment feature coupled to the outermost frame for adjusting a relative position of the vehicle part.

5. The sensor mounting apparatus of claim 4, wherein the at least one additional position adjustment feature comprises at least one of: a yaw adjustment feature; or a translational adjustment feature for moving the vehicle part toward and away from the sensor.

6. The sensor mounting apparatus of claim 5, wherein the yaw adjustment feature comprises a pivot pin coupling the part mounting device to the frame.

7. The sensor mounting apparatus of claim 5, wherein the translational adjustment feature comprises a series of fixture elements slidable for fixing a relative position within at least one of slots or a threaded element causing relative movement of a guide element in a track.

8. The sensor mounting apparatus of claim 1, wherein a first frame of the plurality of frames is configured for relative movement in a vertical direction relative to the sensor mounting device.

9. The sensor mounting apparatus of claim 8, wherein a second frame of the plurality of frames is configured for relative movement in a sideways direction relative to the sensor mounting device.

10. The sensor mounting apparatus of claim 9, wherein respective frame movement in at least one of the sideways direction or the vertical direction is adjustable by a threaded element.

11. The sensor mounting apparatus of claim 10, further comprising at least two guide rods located at an opposite side edge of a respective frame, the guide rods for controlling translational movement.

12. The sensor mounting apparatus of claim 1, wherein a third frame of the plurality of frames is configured for relative movement in a tilting direction relative to an antenna pivot point.

13. The sensor mounting apparatus of claim 1, wherein the sensor mounting device comprises a circular bearing for enabling roll movement of the vehicle part mounting device relative to the sensor.

14. The sensor mounting apparatus of claim 1, wherein at least one of the directional movements or position adjustment is motorised.

15. A method comprising: mounting a sensor to a sensor mount; and mounting a vehicle part to a vehicle part mount, the vehicle part mount arranged proximate to, but for independent movement relative to, the sensor, the independent relative movement comprising at least three degrees of freedom.

16. The method of claim 15, wherein the at least three degrees of freedom comprise at least three of: forward and back, left and right, up and down, roll, or yaw and pitch.

17. The method of claim 15, wherein the sensor mount is fixed to a robotic arm.

18. A sensor testing apparatus, comprising: a sensor mounting plate for mounting a sensor; and a vehicle part mounting device, for mounting a vehicle part, extending from the sensor mounting plate, the vehicle part mounting device configured to be movable in at least three different directions relative to the sensor mounting plate.

19. The sensor testing apparatus of claim 18, wherein the vehicle part mounting device is comprised of a plurality of frames, each movable in a different direction, and wherein the moveable direction of each frame comprises at least one of: forward and back, left and right, up and down, roll, or yaw and pitch.

20. The sensor testing apparatus of claim 19, wherein: the plurality of frames comprises at least three frames arranged to fit successively inside each other from a largest outermost frame to a smallest innermost frame, the largest outermost frame comprises or is coupled to the vehicle part mounting device with attachment features for attaching to a vehicle part, and vehicle part mounting device comprises at least one additional position adjustment feature coupled to the outermost frame for adjusting a relative position of the vehicle part.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0025] Illustrative embodiments will now be described with reference to the accompanying drawings in which:

[0026] FIG. 1 illustrates a general overview of a first embodiment of sensor testing apparatus;

[0027] FIG. 2 illustrates a front elevation view of a second embodiment of sensor testing apparatus;

[0028] FIG. 3 illustrates a side elevation view of the second embodiment from FIG. 2;

[0029] FIG. 4 illustrates a close-up view of a sensor mounting plate;

[0030] FIG. 5 illustrates an overview of the second embodiment of sensor testing apparatus from FIGS. 2, 3, and 4;

[0031] FIG. 6 illustrates a detailed view of a fascia mounting component from the second embodiment of sensor testing apparatus;

[0032] FIG. 7 illustrates a further overview of the second embodiment of sensor testing apparatus from FIGS. 2, 3, 4, 5, and 6, where a robotic arm is visible;

[0033] FIG. 8 illustrates an overview of a third embodiment of sensor testing apparatus, in tilted configuration;

[0034] FIG. 9 illustrates an overview of the third embodiment, in yaw-adjusted configuration; and

[0035] FIG. 10 illustrates an exploded component view of the third embodiment of sensor testing apparatus.

DETAILED DESCRIPTION

[0036] The following description presents example embodiments and, together with the drawings, serves to explain principles of the disclosed sensor mounting apparatus and associated method. However, it is not intended that the scope of the disclosed sensor mounting apparatus and associated method is to be limited to the precise details of the embodiments or exact adherence with all features and/or method operations, since variations will be apparent to a skilled person and are deemed also to be covered by the description. Terms for components used herein should be given a broad interpretation that also encompasses equivalent functions and features. In some cases, several alternative terms (synonyms) for structural features have been provided but such terms are not intended to be exhaustive. Descriptive terms should also be given the broadest possible interpretation; e.g. the term comprising as used in this specification means consisting at least in part of such that interpreting each statement in this specification that includes the term comprising, features other than that or those prefaced by the term may also be present. Related terms such as comprise and comprises are to be interpreted in the same manner. Directional terms such as vertical, horizontal, up, down, sideways, upper and lower are used for convenience of explanation usually with reference to the orientation shown in illustrations and are not intended to be ultimately limiting if an equivalent function can be achieved with an alternative dimension and/or direction. Indeed, in the present case a term such as horizontal axis or vertical axis can be affected by the orientation imposed on the sensor mounting structure by the robotic arm. Therefore, directional terms are relative to each other.

[0037] The description herein refers to embodiments with particular combinations of operations or features, however, it is envisaged that further combinations and cross-combinations of compatible operations or features between embodiments will be possible. Indeed, isolated features may function independently as an implementation of the disclosed sensor mounting apparatus and associated method from other features and not necessarily require implementation as a complete combination.

[0038] It will be understood that the illustrated embodiments show applications only for the purposes of explanation. In practice, the disclosed sensor mounting apparatus and associated method may be applied to many different configurations, where the embodiment is straightforward for those skilled in the art to implement.

[0039] A sensor testing apparatus according to a first embodiment is illustrated by FIG. 1. The testing apparatus or test rig, generally denoted 10, is associated with a sensor that would be affixed to mounting plate 11 by suitable fasteners to a robotic arm A. In use, the arm A would be installed in an anechoic chamber at a distance from an RTS, but the details of the testing procedure are not the subject of the present disclosure. Rather, the disclosure relates to the physical construction of the sensor mounting apparatus, that can be used, for example, in a testing situation, namely a mechanism to independently mount a vehicle part (not shown in FIG. 1, e.g. fascia/bumper) relative to a sensor (not shown) attached to the sensor mounting plate 11.

[0040] In the illustrated form of FIG. 1, the apparatus primarily consists of three frames surrounding the mounting plate 11 that, combined, are able to move the fascia through at least three degrees of freedom relative to an antenna middle point P (also known as a pivot point). A first innermost frame 12 surrounds the sensor mounting plate 11 and, in this embodiment, is configured for vertical movement relative thereto, while a second mid-frame 13 surrounds the first frame and is, in this embodiment, configured for sideways movement relative thereto (and the sensor mount plate 11).

[0041] A third, largest and outermost, frame 14 is, in this embodiment, pivotally connected to brackets 15 extending forwardly from opposing sides of the second frame 13 and configured for adjusting/tilting its pitch about a generally horizontal axis H, relative to the other frames 12/13 and centrally located sensor mount plate 11.

[0042] As mentioned, the first frame 12 is moveable up and down relative to the sensor mount 11 (which in turn is attachable to the robotic arm A). Adjustment may be achieved by a first threaded element 16, arranged vertically through one side (in this case the lower edge) of frame 12, via a receiving threaded opening 12a. A proximate end of element 16 acts against an adjacent edge 11a of the sensor mount 11. Force applied via extension of first threaded element 16 through and from first frame 12 causes vertical translation and an increase in the distance between the lower edge of frame 12 and adjacent edge 11a of the sensor mount plate 11.

[0043] Translational movement in the vertical direction is controlled by at least two guide rods 17 (unthreaded) extending from the opposite (upper) edge 11b of sensor mount plate 11 through unthreaded openings 12b in an adjacent side/edge of first frame 12. Widening the distance between frame 12 and plate edge 11a at the threaded member side causes a corresponding narrowing of the distance between sensor plate edge 11b and frame 12. Accordingly, controlled translational vertical/up/down movement is achieved between the first frame and sensor mount.

[0044] A second frame 13 is provided, moveable left and right relative to the first frame 12 and sensor mount 11, by adjustment of a second threaded member 18 arranged on a horizontal axis at an edge of the second frame 13 (perpendicular to the edge 12b), acting against an adjacent face of the first frame 12. Meanwhile, a second set of guide rods 19, extending from an opposite side edge of the first frame 12 through unthreaded openings (visibility obscured by the third frame 14) in the adjacent edge of the second frame, enable controlled translational sideways/left/right movement between the second frame 13 and, effectively, both the first frame 12 and sensor mount 11.

[0045] A third frame 14 is provided, moveable for pitch rotation about the horizontal axis H, relative to the first/second frames (12/13) and sensor mount 11. Pitch adjustment is enabled by a rotatable knob 20 (e.g. which may have markings to indicate angular displacement) arranged on the horizontal axis H, at a vertical side edge of the third frame 14, and controls tilt movement between the third frame 14 and each of the first/second frame (12/13) and sensor mount 11.

[0046] The third frame 14 ultimately supports a vehicle part (not shown) via mounting brackets 21 such that it is able to move independently relative to the centralized sensor attached to mount 11. By the combination of frames 12, 13 and 14, the vehicle part is able to be manually adjusted in each of the vertical, sideways and tilting directions.

[0047] The third frame may comprise additional adjustment features associated with brackets 21. One such adjustment is a yaw rotation about a vertical axis V, where a part mounting device 22 is pivotally mounted relative to the third frame 14 by a pin/bearing 23. In the illustrated form there are a pair of part mounting devices 22 pivotally mounted to upper and lower side edges respectively of outer frame 14. The part mounting devices 22 move independently of each other relative to frame 14.

[0048] A further adjustment capability of part mounting device 22 is a forward/backwards translational movement along an axis F enabled by threaded rods 24 (manually turned by a knob unseen in FIG. 1) causing relative movement of a guide element in a track 24a for control. Such a function enables the vehicle part mounted from brackets 21 to be moved toward and away from the sensor attached to mount 11 and provides a further degree of freedom of movement. Additional movement variations are possible if the part mounting devices 22 are arranged independently and to different parameters, e.g. different pivot angle and/or forward/backwards amount.

[0049] A sixth, roll, degree of movement may be possible by incorporating a circular bearing (not shown) into the sensor mounting plate 11, such that the sensor itself is fixed in the centre of the circle to the robot arm A, but the entire framework 10 may be rotated about the front facing axis F about the circular bearing.

[0050] The frames, at least when viewed from a frontal direction (see FIG. 2 embodiment), may fit one within the next from smallest to largest, although from a side elevation perspective (see FIG. 3) the third frame 14 may be located forward from the second frame, via bracket 15, so it is clear of the guide rods extending between first 12 and second 13 frames which control translation movement.

[0051] FIGS. 2, 3, 4, 5, 6, and 7 illustrate an alternative embodiment that is functionally similar to the first, except in details of the adjustment mechanism for the part mounting device 22. The same reference numerals are otherwise employed where there is a directly correlated function.

[0052] In this embodiment the part mounting device 22, best seen in FIG. 5, is adjustably attached to the third frame 14 by a series of slotted brackets 25 (also shown in the part view of FIG. 6). Bolt heads 26 provide for tightening or loosening the relative position of the part mounting device 22, including a yaw adjustment if the bolts are set at different relative positions in their respective slots. An outwardly tapering blade 27 extending outwardly from the sensor mount apparatus may have foam adhered to it or other means of holding a vehicle part in place for use in testing.

[0053] With particular reference to FIGS. 3 and 5, the outer and largest frame 14 effectively has two extending arms, on the top and at the bottom. The frame 14 and these arms control the azimuth tilt (e.g. around H axis) and they include the function, via threaded adjustment, to move the mounted fascia along the F axis (back and forth).

[0054] The shape of the fascia may have a strong free form, such that further mounting elements are needed. For example, flexible 3D printed clips that can also take the bent form of complex fascia shapes and be able to fix a position with screws.

[0055] The mounting blades 27 in the second embodiment are preferably 3D printed parts, which may be located into countersinks of the part mount 22. As mentioned, these allow absorber material/foam to be glued in place, which may be important for radar performance test and result authenticity.

[0056] Referring to FIG. 4, a sensor unit (not shown) may be mounted in use with the mounting plate 11 via an asymmetrical mating shape 28. The shape 28 is located on the front side, whereas the rear side of plate 11 is fixed against the robot arm, e.g. via frontally accessed (four) screw pattern 29. Mating shape 28 ensures the Poka-Yoke position of the radar sensor (not shown) to be fool-proofed so that the axes of the device 10 are assured to go through the radar pivot point. The sensor may be mounted to plate 11 by a single screw.

[0057] FIG. 7 provides an overview of sensor mounting apparatus 10 in use, as attached to the robotic arm A. A radar sensor S is shown in place on plate 11 at the centre of the apparatus, with frames 12, 13 and 14 cascading outwardly from it. Sensor S sits behind ghost lines G that represent the field of view of the radar.

[0058] It will be apparent to a skilled person that robotic arm A can position sensor S where it is needed, relative to an RTS in an anechoic chamber, and spatially fix it at that position. Then, after initial calibration measurements, a vehicle part can be attached to blades 27 (or brackets 21 of FIG. 1) and adjusted to any of a variety of positions relative to the fixed sensor S for further measurements to be taken.

[0059] FIGS. 8 to 10 show a third embodiment of testing apparatus 10, with analogous function to the foregoing embodiments, hence common reference numerals are used.

[0060] A tilted configuration is shown in FIG. 8, where outer frame 14 has its pitch adjusted (via manual knob 20) relative to mid-frame 13 and the other inner components that are translated in sideways and vertical directions relative to the sensor mount.

[0061] FIG. 9 illustrates a variation in execution from previous embodiments in that a yaw adjustment knob 30 is provided for adjusting the angle of a part attachment device 22 relative to the outer frame 14. Furthermore, vehicle attachment features would be affixed to extend forwardly from the device 22 at position 21, e.g. past knob 30. As with other embodiments, a toward and away translational motion for a vehicle part (not shown) relative to a sensor (not shown) is controllable by a threaded member and/or guide rods 24 of the yaw adjustable device 22.

[0062] FIG. 10 illustrates a component view of the test rig where it can be seen that each frame may be constructed from multiple sides fixed together by screws to. An assembly procedure will be apparent to a person skilled in the art.

[0063] By way of summary, the disclosure can generally be embodied by a sensor mounting apparatus and associated method, e.g. for use in testing of a vehicle sensor in an anechoic chamber (e.g. a radar sensor). The apparatus features a sensor mounting device for mounting the sensor and a vehicle part mounting device, e.g. comprised of first, second and third frames. Each frame is movable in a different direction relative to the sensor and each other frame, e.g. either adjustable: forward and back, left and right, up and down, and/or via roll, yaw and pitch. The outermost frame further includes an attachment means for holding a vehicle part (e.g. a vehicle fascia/bumper) in place and, optionally, provision for further spatial adjustment of the part relative to the sensor in use, e.g. via a pivot mounting enabling yaw movement.

[0064] Unless context dictates otherwise, use herein of the word or may be considered use of an inclusive or, or a term that permits inclusion or application of one or more items that are linked by the word or (e.g., a phrase A or B may be interpreted as permitting just A, as permitting just B, or as permitting both A and B). Further, the use of preferred, preferably, and grammatically related terms means that a specified element or technique is more acceptable than another, but not that such specified element or technique is a necessity, unless the context clearly dictates otherwise. Also, as used herein, a phrase referring to at least one of a list of items refers to any combination of those items, including single members. For instance, at least one of a, b, or c can cover a, b, c, a-b, a-c, b-c, and a-b-c, as well as any combination with multiples of the same element (e.g., a-a, a-a-a, a-a-b, a-a-c, a-b-b, a-c-c, b-b, b-b-b, b-b-c, c-c, and c-c-c, or any other ordering of a, b, and c). Further, items represented in the accompanying figures and terms discussed herein may be indicative of one or more items or terms, and thus reference may be made interchangeably to single or plural forms of the items and terms in this written description.