Roof-top autonomous vehicle control system

Abstract

A novel roof-top autonomous vehicle control system for converting a non-autonomous vehicle into an autonomous vehicle includes a weatherproof housing that removably attaches to the roof of a host vehicle. The housing supports modular attachment of various sensors, receivers, computers, and other electrical components that can be installed, removed, and/or interchanged without disrupting the initial calibration thereof. In a particular embodiment, various internal electrical components of the system are mounted on a tray which can be mounted in, and removed from, the housing without disrupting the initial calibration of the various sensors. In a more particular embodiment, the housing includes a plurality of removable panels and windows that provide access to the inside of the housing.

Claims

1. An autonomous vehicle control system for converting a host non-autonomous vehicle to an autonomous vehicle, said autonomous vehicle control system comprising: a housing including a mount, said mount being configured to removably attach said housing to the exterior of a host vehicle; a set of sensors coupled to said housing, a first sensor of said set of sensors being configured to sense at least one physical aspect of said host vehicle's driving environment and to provide sensor output corresponding to said at least one physical aspect of said host vehicle's driving environment; an electronic control unit disposed in said housing, said electronic control unit being configured to receive said sensor output and to generate vehicle control instructions based at least in part on said sensor output; a hardware communications interface configured to communicate said vehicle control instructions from said electronic control system to a control module of said host vehicle, said vehicle control instructions configured to control movement of said host vehicle; and a tray; and wherein said tray is configured to be removably mounted in said housing; said electronic control unit is mounted to said tray; said electronic control unit remains mounted to said tray when said tray is removed from said housing; and said first sensor remains mounted to said housing when said tray is removed from said housing; said housing is attached to said vehicle via said mount; said first sensor is fixed to said vehicle via said housing and said mount; and said housing facilitates the removal of said tray with said electronic control unit mounted thereon without changing a position of said first sensor with respect to said vehicle.

2. The autonomous vehicle control system of claim 1, wherein said first sensor is a LiDAR sensor.

3. The autonomous vehicle control system of claim 1, including a second sensor, and wherein said second sensor remains mounted to said tray when said tray is removed from said housing.

4. The autonomous vehicle control system of claim 3, wherein said second sensor is a camera.

5. The autonomous vehicle control system of claim 1, wherein said autonomous vehicle control system is a modular system having at least one physical interface configured to receive a plurality of different sensors.

6. The autonomous vehicle control system of claim 1, wherein said first sensor is a LiDAR sensor.

7. The autonomous vehicle control system of claim 6, wherein: said set of sensors further includes a second sensor; and said second sensor is a camera.

8. The autonomous vehicle control system of claim 7, further comprising an antenna set mounted to said housing and electrically connectable to said electronic control unit.

9. The autonomous vehicle control system of claim 6, further comprising an antenna set mounted to said housing and electrically connectable to said electronic control unit.

10. The autonomous vehicle control system of claim 1, further comprising an antenna set mounted to said housing and electrically connectable to said electronic control unit.

11. The autonomous vehicle control system of claim 10, wherein said antenna set includes: a positioning antenna; and a communications antenna.

12. The autonomous vehicle control system of claim 1, wherein said first sensor is a camera.

13. The autonomous vehicle control system of claim 1, wherein said mount includes a plurality of legs extending outward and downward from a central portion of said housing to suspend said housing over the roof-top of said host vehicle.

14. The autonomous vehicle control system of claim 1, wherein said mount is adjustable to facilitate mounting said housing on a plurality of different vehicle models.

15. The autonomous vehicle control system of claim 1, wherein said electronic control unit further includes a wireless communication device.

16. The autonomous vehicle control system of claim 1, wherein said electronic control unit further includes a positioning device.

17. The autonomous vehicle control system of claim 1, wherein said electronic control unit is configured to wirelessly communicate with control systems of other autonomous vehicles.

18. The autonomous vehicle control system of claim 1, wherein said electronic control unit is configured to wirelessly communicate with a traffic control system.

19. The autonomous vehicle control system of claim 1, further comprising said vehicle, and wherein: said housing is attached to said vehicle via said mount; said first sensor is fixed to said vehicle via said housing and said mount; and said tray with said electronic control unit mounted thereon is removed from said housing and, thereby, disconnected from said vehicle.

20. The autonomous vehicle control system of claim 1, wherein: said housing includes at least one removable panel and a frame, said frame being disposed in a second position with respect to said vehicle; said at least one removable panel is configured to be removed from said housing to provide access to said tray while maintaining said second position of said frame with respect to said vehicle; and said first sensor is fixed to said housing via said frame.

21. The autonomous vehicle control system of claim 1, wherein: said housing defines an internal volume and an exterior surface; said tray is disposed within said internal volume; and said first sensor is fixed to said exterior surface of said housing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention is described with reference to the following drawings, wherein like reference numbers denote substantially similar elements:

(2) FIG. 1 is a front perspective view of an autonomous vehicle control unit mounted on the roof a hosting vehicle;

(3) FIG. 2 is rear perspective view of the unit of FIG. 1;

(4) FIG. 3 is a top view of the unit of FIG. 1;

(5) FIG. 4 is a rear view of the unit of FIG. 1;

(6) FIG. 5 is a side view of the unit of FIG. 1;

(7) FIG. 6 is a front view of the unit of FIG. 1;

(8) FIG. 7 is a top view of the unit of FIG. 1;

(9) FIG. 8 is a side view of the unit of FIG. 1;

(10) FIG. 9 is a table of example electronic components of the unit of FIG. 1;

(11) FIG. 10 is a front perspective view of another example autonomous vehicle control unit;

(12) FIG. 11 is a rear perspective view of the unit of FIG. 10;

(13) FIG. 12 is a front perspective view of the unit of FIG. 10 with a top panel removed;

(14) FIG. 13 is a rear perspective view of the unit of FIG. 10 with a top panel removed;

(15) FIG. 14 is a front perspective view of the unit of FIG. 10 with both top panels removed;

(16) FIG. 15 is a rear perspective view of the unit of FIG. 10 with both top panels and center strut removed;

(17) FIG. 16 is a front perspective view of some electrical components of the unit of FIG. 10;

(18) FIG. 17 is a rear perspective view of some electrical components of the unit of FIG. 10;

(19) FIG. 18 is a top view of the electrical components of the unit of FIG. 10; and

(20) FIG. 19 is a block diagram of autonomous vehicle system showing an autonomous vehicle communicating with another autonomous vehicle and a traffic control system.

DETAILED DESCRIPTION

(21) The present invention overcomes the problems associated with the prior art, by providing a shockproof and weatherproof autonomous unit that can be universally mounted on the roof of various vehicles. In the following description, numerous specific details are set forth (e.g., materials, specific geometries, configurations, etc.) in order to provide a thorough understanding of the invention. Those skilled in the art will recognize, however, that the invention may be practiced apart from these specific details. In other instances, details of well-known manufacturing practices (e.g., sheet metal forming, gasket forming, etc.) and autonomous vehicle components (e.g., computer programming, drive wire details, etc.) have been omitted, so as not to unnecessarily obscure the present invention.

(22) FIG. 1 shows a front perspective view of an autonomous vehicle control unit 100, according to a first example embodiment of the present invention. In the example embodiment, unit 100 is shown removably mounted on a rooftop 102 of a hosting vehicle 104 by a set of four footings 106 which, in this example, are Yakima footings.

(23) Unit 100 is a universal system that can be removed from vehicle 104 and mounted on a variety of different models. In this example, vehicle 104 is originally a non-autonomous vehicle that is converted to an autonomous vehicle by unit 100 without permanently modifying vehicle 104. Indeed, unit 100 may be removed from vehicle 104 thereby converting it back to a non-autonomous vehicle. Unit 100 includes a plurality of sensors that observe the surrounding driving environment (e.g., presence of nearby moving and stationary vehicles, pedestrians, etc.), a plurality of receivers (e.g. antennas) that receive signals transmitted from remote sources (e.g., cell towers, other autonomous vehicle control units, GPS satellites, etc.), an onboard computer that generates vehicle control instructions (e.g., braking, accelerating, turning, etc.) responsive to data acquired by the sensors and receivers, and an interface that outputs the control instructions to the main computer of the host vehicle.

(24) Unit 100 includes a fully weatherproof housing 108 supported by four legs 110 extending downward therefrom. Housing 108 provides structural support and protection to various electrical components to which it is coupled, including, but not limited to, a center light detection and ranging (LiDAR) sensor 112, two side LiDAR sensors 114, a set of front cameras 116, a first antenna assembly 118, and a second antenna assembly 120. Center LiDAR sensor 112 is a Velodyne LiDAR 32C unit having a 5 inch height adjustability. Each of LiDAR sensors 114 is a Velodyne LiDAR 16 unit mounted on a respective one of front legs 110 at a pitch of 45 degrees and with a pitch adjustability of +/−15 degrees. Cameras 116 include one wide angle camera 122, and two narrow angle cameras 124. First antenna assembly 118 is a Swiftnav GPS antenna assembly having a 150 degree sky line of sight. Second antenna assembly 120 is a 5-in-1 antenna including two cellular/GSM antennas, two wifi antennas, and a GPS antenna.

(25) FIG. 2 shows a rear perspective view of unit 100 mounted on rooftop 102 of vehicle 104. As shown, each of the two rear legs 110 includes a respective mounting pad 200 for optionally mounting additional modular sensors such as, for example, LiDAR sensors, radar sensors, cameras, antennas, etc. Housing 108 further includes two removable side panels 202 and a removable rear panel 204 that provide access into the internal region of unit 100 where additional electrical and mechanical components are mounted.

(26) FIG. 3 shows a top view of unit 100 mounted on rooftop 102 of vehicle 104. As shown, housing 108 further includes removable top panels 300 that provide access into the interior of unit 100. Unit 100 further includes a cable pigtail 302 that facilitates the electrical connection between unit 100 and a backup computing system in the trunk of vehicle 104 and/or a drive wire of vehicle 104.

(27) FIG. 4 shows a rear view of unit 100 mounted on rooftop 102 of hosting vehicle 104.

(28) FIG. 5 shows a side view of unit 100 mounted on rooftop 102 of hosting vehicle 104.

(29) FIG. 6 shows a front view of unit 100 mounted on rooftop 102 of hosting vehicle 104.

(30) FIG. 7 is a top view of unit 100 showing internal components thereof in a “phantom” view. Unit 100 further includes a computer 700 and miscellaneous electronics 702. Computer 700 is electrically connected to control and communicate with electronics 702 and the various other electrical components of unit 100. Responsive to the input from the various sensors and commands received from local and/or remote interface devices, computer 700 provides control signals to vehicle 104, via cable pigtail 302 (FIG. 3) and the “drive wire” (not shown) of vehicle 104.

(31) FIG. 8 is a side view of unit 100 showing internal components thereof in “phantom’ view.

(32) FIG. 9 shows a table-A including various electrical components of unit 100.

(33) FIG. 10 shows a front perspective view of another example modular autonomous vehicle control unit 1000. Unit 1000 is configured to be universally and removably mounted on the rooftops of a wide variety of vehicle models.

(34) Unit 1000 includes a housing 1002, four legs 1004, four feet 1006, a center LiDAR 1008, two front LiDARs 1010, a first antenna assembly 1012, a second antenna assembly 1014, and various internal electrical components (visible in FIG. 16). Housing 1002 protects the internal components of unit 1000 from elements such as moisture and debris. Housing 1002 is made up of a plurality of removable panels including two side panels 1016, a rear panel 1018 (visible in FIG. 11), two top panels 1020, and a front window 1022. In this example, front window 1022 permits the passage of light but is impermeable to moisture, so as to protect an underlying camera assembly without impeding its functionality. Legs 1004 extend from housing 1002 to support and mount unit 1000 over the rooftop of an automobile. Each of feet 1006 is removably mounted on the bottom of a respective one of legs 1004, to facilitate the mounting of unit 1000 to the rooftop. In this example, feet 1006 are manufactured by Yakima. Center LiDAR 1008 is a Velodyne 32C unit and both of front LiDARs 1010 are Velodyne LiDAR 16 units. First antenna assembly 1012 is a SwiftNav unit and second antenna assembly 1014 is a 5-in-1 antenna including two cellular/GSM antennas, two wifi antennas, and a GPS antenna. Unit 1000 further includes a set of hole-plugs 1024 that can be removed to access underlying universal electrical and mechanical component receivers, which are configured to accept modular components including, but not limited to, LiDAR units, cameras, radars, lights, etc.

(35) FIG. 11 shows a rear perspective view of unit 1000. As shown, panel 1018 includes a plurality of through-holes 1100 that permit the passage of cables through housing 1002. The cables (not shown) facilitate the electrical connection between internal components of unit 1000 and a drive/computing system of a host vehicle.

(36) FIG. 12 shows a front perspective view of unit 1000 with one of top panels 1020 removed to access the interior space 1200 of unit 1000, and plugs 1024 removed to access modular electrical/mechanical interfaces 1202. As shown, panels 1020, interfaces 1202, and LiDAR 1008 are supported on a central strut 1204.

(37) FIG. 13 shows a rear perspective view of unit 1000 with one of top panels 1020 removed to access the interior space 1200 of unit 1000.

(38) FIG. 14 shows a front perspective view of unit 1000 with both of top panels 1020 removed.

(39) FIG. 15 shows a rear perspective view of unit 1000 with both of top panels 1020, strut 1204, and LiDAR 1008 removed.

(40) FIG. 16 shows a front perspective view of the various electrical components of unit 1000. Many of the various electrical components of unit 1000 are mounted on a tray 1600, which is mounted on a chassis 1602. Tray 1600 is screwed to chassis 1602 with a plurality of resilient shock absorbing washers disposed therebetween. Tray 1600 and the various electrical components mounted thereon are, together, removable from unit 1000 by unscrewing tray 1600 from chassis 1602 and then lifting tray 1600 out of unit 1000.

(41) The various electrical/electronic components include, but are not limited to, a computer 1604, three electrical units 1606, a first camera 1608, a second camera 1610, and a third camera 1612. Computer 1604 is electrically connected to the various electrical systems of unit 1000 through an interface panel 1614 adapted to receive connectors from various sensor systems. Each of the three electrical units 1606 includes the complementary electronics of a respective one of the three LiDARs 1008 (top, center), 1010 (driver side), and 1010 (passenger side). Camera 1608 is a narrow angle camera, camera 1610 is a wide angle camera, and camera 1612 is a low light camera (e.g., near infra red).

(42) FIG. 17 shows a rear perspective view of the various electrical components of unit 1000 mounted on tray 1600, including additional components not completely visible in FIG. 16. The electrical components further include a rear camera 1700, an inertial navigation system (INS) 1702, a CraddlePoint LTE unit 1704, a set of Netgear Ethernet switches 1706, a SwiftNav electronics unit 1708, and a DC power bus 1710. Camera 1700 is a rear facing wide angle camera. INS 1702 is mounted at a centerline of unit 1000 to measure pitch, tilt, and yaw. CraddlePoint LTE unit 1704 is an internet modem. SwiftNav electronics unit 1708 houses various electronic components for antenna assembly 1012. DC power bus 1710 provides DC power to the various components of unit 1000.

(43) FIG. 18 shows a top view of the various electrical components of unit 1000. As shown, the various electronic components of unit 1000 further include a USB hub 1800. The connecting cables of unit 1000 are omitted from the drawings, so as not to unnecessarily obstruct the views of the other components.

(44) FIG. 19 is a block diagram of autonomous vehicle system 1900 showing an autonomous vehicle communicating with another autonomous vehicle and a traffic control system 1902. More specifically, in this particular example, vehicle control unit 100.sub.1 on host vehicle 104.sub.1 is communicating with vehicle control unit 100.sub.n on host vehicle 104.sub.n. However, it should be understood that either vehicle could be a fully integrated autonomous vehicle, as opposed to a converted non-autonomous vehicle.

(45) Traffic control system 1902 is shown representationally as a “smart traffic light.” However, it should be understood that traffic control system 1902 can be embodied in a wide range of devices capable of communicating with vehicle control units 100. Traffic control system 1902 can be as simple as simple as a single device transmitting its current state (e.g., signal light color, speed limit, etc.) or a wide network of hundreds of devices spanning miles of streets and highways communicating any type of useful information (traffic conditions, weather conditions, emergency conditions, and so on) to any autonomous vehicles within range.

(46) A positioning system 1904 provides positioning signals to control units 100, which enable control units 100 to precisely determine their current positions. In addition, control units 100 can wirelessly communicate with each other either directly or via a communications network 1906. Communication between autonomous vehicles will greatly improve safety and efficiency of traffic flow, among other things. For example, one vehicle being informed of another vehicle's intention to make a lane change could slow down to allow the lane changing vehicle into the lane. As another example, one vehicle can be informed that another vehicle in front of it intends to reduce speed. Virtually any useful information can be communicated between control units 100.

Overview of One Example Embodiment

(47) 1. Aesthetically matching with Vehicle and Application Sensor unit, antennas and sensor mounts, and panels are designed in such a way that is form fitting, color matching, and attractive for use in marketing and demonstration purposes Sensor unit exterior dimensions and form can conform to industrial design and layout presented on FIGS. 1-6. Sensor unit exterior logo and paint scheme can conform to FIGS. 1-6.

(48) 2. Components/Electronics to be mounted and supported Sensor unit can mount to a 2018 Ford Fusion vehicle roof on the left and right edges Computer, LiDAR electronics, cameras, and electronics can be mounted per FIGS. 7-8 Internal component mount and supports can be designed for versatility and ease of reconfiguration Cable harnesses from internal components can be routed and bundled to exit the sensor unit at one rear location through a waterproof cable gland The sensor unit cable pigtail can be 2 ft in length and connectorized

(49) 3. Modularity and Serviceability of components and subsystems Assemblies are designed in parts/modules that are easily separable and accessible Parts are designed in such a way that installation, removal, maintenance, and modification have minimal impact/changes on other parts within the system Sensors can retain calibration upon disassembly and reassembly by using locating features such as dowel pins and bosses Mounting feet can be easily separable/replaceable from the main housing of the unit to accommodate changes in vehicle types and roof dimensions

(50) 4. Scalability Parts can to be designed for manufacturability using standard shop processes Components and modules are designed for low volume production (less than 100) Initial prototype quantity is two units sequentially with learning on first unit applied to second unit. Option of increasing production for high volume manufacturing

(51) 5. Reliability Components are designed to withstand functional and durability testing on public roads

(52) 6. Quality Components are designed to use automotive rated parts and materials where practical Workmanship should conform to industry standards and spec TBD (e.g., ISO26262, IPC 610)

(53) 7. Adjustability Side LiDARs can have pitch adjustability of +/−15 degrees from the nominal orientation Center/top LiDAR height adjustability of +/−5 inches Center/top LiDAR does not require pitch adjustability in some embodiments

(54) 8. Loads The sensor unit can withstand static, dynamic, aerodynamic, and shock loads common to vehicles traveling 50 mph 90% of the time with occasional highway driving at 75 mph around San Francisco bay area The sensor unit can withstand 2 years of testing without structural failure Safety factor of 2 can be used for design and calculations

(55) 9. Aerodynamic and low airflow noise Exterior components and panels are designed to minimize drag and reduce wind noise

(56) 10. Upgradability and Vehicle Agnostic Ability to add cameras to side and rear panels Ability to add display (e.g., LCD) to side panels Able to switch out center LiDAR (or any other components) for alternate supplier (pandar 40) Future upgradability to other vehicles (e.g., Chrysler Pacifica, etc.). Sensor unit main “housing” can remain unchanged while mounting leg/arm can be vehicle specific

(57) The description of particular embodiments of the present invention is now complete. Many of the described features may be substituted, altered or omitted without departing from the scope of the invention. For example, alternate object detection devices (e.g. radar), may be substituted for the LiDARs. As another example, alternate modular sensors (e.g., LiDAR, radar, camera, etc.) may be added to interfaces 1202. These and other deviations from the particular embodiments shown will be apparent to those skilled in the art, particularly in view of the foregoing disclosure.