DRIVER ASSIST SYSTEM HAVING BURNISHED CAMERA MOUNT

A driver assist system for a vehicle includes a module. A camera assembly is connected inside the module. The camera assembly includes a burnished camera mount and a camera lens connected to the burnished camera mount. The camera lens extending into the camera mount.

FIELD OF THE INVENTION

The present invention relates to a driver assist system and, in particular, to a burnished camera mount of a driver assist system.

BACKGROUND TO THE INVENTION

In order to assist a driver in operating a vehicle, it is known to dispose various devices in a module that is attached to the vehicle. The devices in the module can include a rain sensor, a temperature sensor, and/or a camera assembly. The camera assembly can, for example, monitor lane departure, assist in maintaining the vehicle in a road lane, provide lane centering/guidance, control operation of the high and/or low beam headlights, detect vehicle presence, provide forward crash warning, perform sign recognition, and/or apply automatic emergency braking in response to the detection of a pedestrian.

The output of the camera can be connected to main control circuitry that analyzes the camera output. It can be important to maintain the optical focus of the camera in order to ensure proper function of the module. One aspect of maintaining the optical focus of the camera can be ensuring the integrity of the camera mount, which locates the camera in the module. Specifically, it can be desirable to ensure that the mounting section does not corrode. Although it has been suggested that the mounting section be manufactured out of corrosion resistant materials (i.e., plastic) it can be desirable to manufacture the mounting section out of metal in order to assist in camera heat dissipation.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a driver assist system for a vehicle includes a module. A camera assembly is connected inside the module. The camera assembly includes a burnished camera mount and a camera lens connected to the burnished camera mount. The camera lens extending into the camera mount.

DETAILED DESCRIPTION

A module50(FIGS. 1 and 2) houses one or more devices that can facilitate controlling aspects of vehicle operation. In one example, the module50is of the type described in U.S. Patent Application Pub. No. 2012/0013741 A1, the entirety of which is herein incorporated by reference. The module50can, for example, house a rain sensor52, a humidity sensor (not shown), a temperature sensor (not shown), and/or a camera assembly100. It is contemplated that the module50can house any number of devices. The module50can be mounted on a windshield60of a vehicle via a mounting bracket62. It is contemplated that the module50can be mounted on any other desired portion of a vehicle and/or be mounted using means other than the disclosed mounting bracket62.

The camera assembly100according to one embodiment of the present invention is shown inFIGS. 3-5. First fasteners102attach a printed circuit board104to a camera mount200. A camera lens106is received in the camera mount200. A first end portion108of the camera lens106is disposed adjacent to an image sensor110provided on the printed circuit board104. The image sensor110converts an optical image that is transmitted through the camera lens106into an electrical signal. A flex connector112communicates the electrical signal generated by the image sensor110to main control circuitry64(FIG. 2) that analyzes the output of the image sensor110.

Second fasteners114anchor the camera assembly100in the module50. When the camera assembly100is anchored in the module50by the second fasteners114, a second end portion116of the camera lens106is disposed in an opening74provided on the module50. The opening74provides the camera assembly100with a field of view outside of the module50.

The camera mount200is shown in further detail inFIGS. 6-11. The camera mount200includes a front side210(FIG. 6), a back side220(FIG. 7), a top side230(FIG. 8), a bottom side240(FIG. 9), a right side260(FIG. 10), and a left side270(FIG. 11). As used in this disclosure, the orientation of the right side260and left side270is made with respect to the field of view of the camera assembly100. The camera mount200has a length that extends from the right side260to the left side270, a height that extends from the top side230to the bottom side240, and a width that extends from the front side210to the back side220.

The camera mount200includes a main body300. In one example, the main body300is substantially cuboid shaped. However, it is contemplated that the main body300can be any desired shape. The main body300has an upper face302and a lower face304, a left side face306and a right side face308, and a front face310and a rear face312.

The camera lens106is received in an opening314provided in the main body300. The opening314extends completely through the width of the main body300. In one example, the opening314is substantially cylindrical shaped. However, it is contemplated that the opening314can be any desired shape. The rear face312of the main body300abuts against the printed circuit board104when the printed circuit board104is attached to the camera mount200by the first fasteners102. With the printed circuit board104abutting the rear face312, the image sensor110is received in a depression316(FIG. 5) provided on the rear face312. The depression316extends into the rear face312and toward the front face310. In one example, the perimeter of the depression316is substantially square so as to mimic the substantially square perimeter of the image sensor110. However, it is contemplated that the perimeter of the depression316and/or the image sensor110can be any desired shape.

The camera mount200(FIGS. 6-11) further includes a first arm400. The first arm400extends away from the right side face308of the main body300. In one example, the width of the first arm400is less than the width of the main body300(seeFIGS. 8 and 9). However, it is contemplated that the first arm400may have any desired width.

The first arm400includes a first section410and a second section412. The first section410extends directly away from the main body300and spaces the second section412from the main body300along the length of the camera mount200. In one example, the height of the first section410is greater than the height of the second section412(seeFIGS. 6 and 7). However, it is contemplated that the height of the first section410can be less than, or equal to, the height of the second section412.

Fastener apertures422are provided in the first section410. The fastener apertures422extend completely though the width of the first arm400. The fastener apertures422receive the first fasteners102that attach the printed circuit board104to the camera mount200.

The camera mount200further includes a first attaching section500. The first attaching section500is provided at an end of the first arm400. The first arm400spaces the first attaching section500away from the main body300along the length of the camera mount200. In one example, the first attaching section500is substantially cylindrical. However, it is contemplated that the first attaching section500can be any desired shape. An aperture504extends completely through the width of the first attaching section500. The aperture504receives the second fastener114that anchors the camera mount200in the module20.

In one example, the width of the first attaching section500is greater than the width of the first and second sections410,412of the first arm400. The height of the first attaching section500is equal to the height of the second section412of the first arm400. However, it is contemplated that width of the first attaching section500can be less than, or equal to, the width of the first and second sections410,412of the first arm400. Additionally, it is contemplated that the height of the attaching section500can be greater than, or less than, the height of the second section412of the arm.

The camera mount200further includes a second arm400′ and a second attaching section500′. The second arm400′ extends away from the left side face306of the main body300. The second attaching section500′ is provided at an end of the second arm400′. The second arm400′ spaces the second attaching section500′ away from the main body300along the length of the camera mount200. The second arm400′ and the second attaching section500′ are substantially similar to the first arm400and the first attaching section500, respectively. As such, the specifics of the second arm400′ and the second attaching section500′ will not be described further. Features of the second arm400′ and the second attaching section500′ that are similar to the features of the first arm400and the first attaching section500, respectively, will be identified with like numerals appended with a prime (′).

High stress concentration areas can be present at various points of the camera mount200. The high stress concentration areas can be created due to a variety of reasons including, for example, the design of the casting used to manufacture the camera mount200, the geometry of parts of the camera mount200, and/or porosity in the camera mount200generated during the casting process of the camera mount200. These areas of high stress concentration can be especially susceptible to corrosion. In order to improve the robustness of the module50, portions of the camera mount200can be burnished to ward off corrosion.

For the purposes of illustration, burnished portions600a,600b,600cof the camera mount200are indicated by cross hatching. In one example, a portion600aof the rear face312of the main body300surrounding the depression316and portions600b,600cof the upper and lower faces302,304of the main body300are burnished. The portion600aof the rear face312engages the printed circuit board104when the camera mount is connected to the printed circuit board. It is contemplated that other burnishing arrangements can be provided. For example, the burnished portions600a,600b,600cof the rear face312, the upper face302, and/or the lower face304of the main body300can be expanded or reduced. As another example, other portions of the main body300beyond the aforementioned portions can be burnished. As yet another example, a portion, or portions, of one or more of the first arm400, the second arm400′, the first attaching section500, and the second attaching section500′ can be burnished.

A camera assembly1100according to another embodiment of the present invention is shown inFIGS. 12-14. The camera assembly1100includes a camera mount1200that is secured in a module (not shown). The module can be of the type shown inFIGS. 1 and 2. However, it is contemplated that the camera assembly1200can be used with any desired module. First fasteners1102attach a printed circuit board1104to the camera mount1200. A camera lens1106is received in the camera mount1200. A first end portion1108of the camera lens1106is disposed adjacent to an image sensor1110provided on the printed circuit board1104. The image sensor1110converts an optical image that is transmitted through the camera lens1106into an electrical signal. A flex connector1112communicates the electrical signal generated by the image sensor1110to main control circuitry (not shown) that analyzes the output of the image sensor1110.

Second fasteners1114anchor the camera assembly1100in the module. When the camera assembly1100is anchored in the module by the second fasteners1114, a second end portion1116of the camera lens1106is disposed in an opening provided on the module. The opening provides the camera assembly1100with a field of view outside of the module.

The camera mount1200is shown in further detail inFIGS. 15-20. The camera mount1200includes a front side1210(FIG. 15), a back side1220(FIG. 16), a top side1230(FIG. 17), a bottom side1240(FIG. 18), a right side1260(FIG. 19), and a left side1270(FIG. 20). As used in this disclosure, the orientation of the right side1260and left side1270is made with respect to the field of view of the camera assembly1100. The camera mount1200has a height that extends top side1230to the bottom side1240, a length that extends from the right side1260to the left side, and a width that extends from the front side1210to the back side1220.

The camera mount includes a main body1300. In one example, the main body1300has a cylindrical section1301and a cuboid section1303extending axially from the cylindrical section. However, it is contemplated that the main body1300can be a combination of any desired shapes or a single shape. The main body1300has an upper face1302and a lower face1304, a left side face1306and a right side face1308, and a front face1310and a rear face1312.

The camera lens1106is received in an opening1314provided in the main body1300. The opening1314extends completely through the entire width of the main body1300. In one example, the opening1314is substantially cylindrical shaped. However, it is contemplated that the opening1314can be any desired shape. The rear face1312of the main body1300abuts against the printed circuit board1104when the printed circuit board1104is attached to the camera mount1200by the second fasteners1102. With the printed circuit board1104abutting the rear face1312, the image sensor1110is received in a depression1316provided on the rear face1312. The depression1316extends into the rear face1312and toward the front face1310. In one example, the perimeter of the depression1316is substantially square so as to mimic the substantially square perimeter of the image sensor1100. However, it is contemplated that the perimeter of the depression1316and/or the image sensor1100can be any desired shape.

The camera mount1200further includes a first arm1400. The first arm1400extends away from the right side face1308of the main body1300. In one example, the first arm1400is directly attached to only the cuboid section1303of the main body1300(seeFIGS. 17 and 18). However, it is contemplated that the first arm1400can be directly attached to only the cylindrical section1301. Additionally, it is contemplated that the first arm1400can be directly attached to both the cylindrical section1301and the cuboid section1303.

The first arm1400includes a first section1410, fastener apertures1422, and a second section1412. The first section1410extends directly from the main body1300and spaces the fastener apertures1422from the main body along the length of the camera mount1200. In one example, the height of the first section1410is constant (seeFIG. 16), and the width of the first section1410is tapered (seeFIG. 17). However, it is contemplated that first section1410can have any desired configuration.

The second section1412is provided at the end of the first arm1400. In one example, the height of the second section1412is tapered (seeFIG. 16), and the width of the second section1412is constant (seeFIG. 17). However, it is contemplated that the second section1412can have any desired configuration.

The fastener apertures1422are provided in the second section1412. The fastener apertures1422extend completely through the width of the first arm1400. The fastener apertures1422receive the first fasteners1102that attach the printed circuit board1104to the camera mount1200.

The camera mount1200further includes a first attaching section1500. The first attaching section1500is provided at an end of the second section1412of the first arm1400. The first arm1400spaces the first attaching section1500away from the main body1300along the length of the camera mount1200. In one example, the first attaching section1500is substantially cylindrical. However, it is contemplated that the first attaching section1500can be any desired shape. The first attaching section1500includes an aperture1504that extends completely through the width of the first attaching section1500. The aperture1504receives the second fastener1114that anchors the camera mount1200in the module.

The camera mount1200further includes a second arm1400′ and a second attaching section1500′. The second arm1400′ extends away from the left side face1306of the main body1300. The second arm1400′ includes a first section1410′, fastener apertures1422′, and a second section1412′. The attaching section1500′ is provided at an end of the second section1412′ of the second arm1400′. The construction of the second arm1400′ and the second attaching section1500′ is substantially identical to the first arm1400and first attaching section1500, respectively. As such, the specifics of the second arm1400′ and the second attaching section1500′ will not be described further. Features of the second arm1400′ and the second attaching section1500′ that are similar to the features of the first arm1400and first attaching section1500will be identified by like numerals appended with a prime (′).

As discussed above, high stress concentration areas can be present at various areas of the camera mount1200. To prevent corrosion of the high stress concentration areas, portions1600a,1600b,1600cof the camera mount1200can be burnished. In one example, burnished areas1600(indicated by cross hatching) are provided at a portion1600aof the rear face1312of the main body1300surrounding the depression1316and portions1600b,1600cof the upper and lower faces1302,1304of the main body1300. However, it is contemplated that other burnishing arrangements can be provided. For example, the burnished portions1600a,1600b,1600cof the rear end1312, the upper end1302, and/or the lower end1304of the main body1300can be expanded or reduced. As another example, other portions of the main body1300beyond the aforementioned surfaces can be burnished. As yet another example, a portion, or portions, of one or more of the first arm and the second arm1400,1400′ and the first and second attaching section1500,1500′ can be burnished.

The above described burnishing creates a compressive layer on surfaces of the part of the module to which the camera lens is mounted with minimum cold work. The burnishing enhances localized compressive residual stress and improves the corrosion resistance of the camera mount, thereby improving the robustness of the module. What have been described above are examples of the disclosure. It is, of course, not possible to describe every conceivable combination of components or method for purposes of describing the disclosure, but one of ordinary skill in the art will recognize that many further combinations and permutations of the disclosure are possible. For example, although the burnishing of a specific camera mount has been described, it is contemplated that the burnishing process could be applied to camera mounts having configurations that are different from the camera mount described in the present disclosure. Furthermore, it is contemplated that the burnishing process could be applied to modules having configurations that are different from the module described in the present disclosure. Additionally, it is contemplated that other parts of the module could be burnished to further improve robustness of the module. Accordingly, the disclosure is intended to embrace all such alterations, modifications, and variations that fall within the scope of this application, including the appended claims.