Abstract:
A bumper integrated forward radar mounting system for use with a vehicle is disclosed. The system includes a radar module, a bumper attachment bracket and a bumper extension. The radar module is attached to the bumper attachment bracket. The radar module may comprise one or both of a medium range radar component and a long range radar component. The bumper attachment bracket may be composed of a metal or of a polymerized material selected from one of several plastics, fiberglass or nylon. The bumper extension fitted over the radar module extends from the existing bumper. Radio waves emitted from and received by the radar module must be able to readily pass through the bumper extension without being altered. To be suitable for covering the radar module the bumper extension must be of a uniform thickness, fairly flat and non-metallic with no metal or chrome to interfere with its beam patch.

Description:
TECHNICAL FIELD 
       [0001]    The disclosed invention relates generally to radar systems for automotive vehicles. More particularly, the disclosed invention relates to a bumper integrated forward radar mounting system integrated into the front portion of the front bumper of the vehicle. The radar is attached to a bumper attachment bracket. An extension of the bumper in the form of a cover is provided over the opening to cover the radar module. 
       BACKGROUND OF THE INVENTION 
       [0002]    Many modern vehicles are fitted with radar systems for detecting objects and their relative positions to the vehicle. The most common of these is a rearward radar system. However, forward radar systems are becoming increasingly available on vehicles. These forward radar systems are multifunctional and are able to provide adaptive cruise control and pre-crash braking features as well as other customer features. 
         [0003]    Packaging the radar in the front of the car creates a number of difficulties for the designer. Such packaging is a challenging mixture of often conflicting requirements for cooling, styling and radar performance as well as other requirements. Manufacturers attempt to employ a common package strategy across all cars in a vehicle lineup in an effort to achieve the advantages of reduced cost and complexity while maintaining quality. 
         [0004]    In known arrangements for forward systems, the radars are typically packaged either above or below the front bumper. When positioned above the front bumper the radar provides for better performance but presents styling challenges in that the area above the bumper is ordinarily highly styled. Specifically, upper bumper extensions and grilles ordinarily have complex styling that often includes extensive chrome finishing and other materials not conducive with radar. 
         [0005]    Alternatively, placement of the radar below the front bumper is easier to implement with styling considerations but does not provide the best performance. In addition, the area below the bumper is often the source of most of the vehicle&#39;s cooling air. 
         [0006]    Accordingly, as in so many areas of vehicle technology, there is room in the art of forward radar systems for vehicles for an alternative configuration that provides good performance without sacrificing styling and without adding burdensome manufacturing and assembly costs. 
       SUMMARY OF THE INVENTION 
       [0007]    The disclosed invention provides a bumper integrated forward radar mounting system for use with a vehicle. The system includes a radar module, a bumper attachment bracket and a bumper extension. The radar module is attached to the bumper attachment bracket. The bumper extension is fitted over the radar module. 
         [0008]    The bumper attachment bracket may be composed of a metal such as steel or a polymerized material selected from any one of several plastics, fiberglass or nylon, which may or may not be carbon reinforced. 
         [0009]    The bumper extension fitted over the radar module extends from the existing bumper. Radio waves emitted from and received by the radar module must be able to readily pass through the bumper extension without being altered. Accordingly the bumper extension is made from a material other than a metal, such as any one of several plastics, fiberglass or nylon, which may or may not be carbon reinforced. To be suitable for covering the radar module the bumper extension must be of a uniform thickness, fairly flat and non-metallic with no metal or chrome to interfere with its beam patch. This provides a good match for the bumper covering material. 
         [0010]    The radar module may comprise one or both of a medium range radar component and a long range radar component. Regardless of the number, the radar module is attached to the bumper attachment bracket by any one of several means including but not limited to mechanical fasteners such as press-fitted studs. 
         [0011]    The bumper extension may be flush with the adjacent bumper surface or may be otherwise shaped so as to form a part of the overall design configuration. 
         [0012]    The disclosed invention provides many advantages over known systems. The bumper itself typically has no chrome to interfere with a bumper-mounted radar system. Thus the system may be easily incorporated into a vehicle design. This solution would provide a consistent approach to mounting the forward radar with little or no impact on styling of the vehicle and little or no impact on cooling airflow. Also the cost of a separate mounting bracket insert for the radar will be eliminated or substantial reduced. The system of the disclosed invention also can be used by a manufacturer across all vehicle lines without significant variation, thus reducing design costs and eliminating the need for the manufacturer to design each vehicle from scratch. 
         [0013]    Other advantages and features of the invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein: 
           [0015]      FIG. 1  illustrates a front perspective view of a vehicle front bumper assembly according to the disclosed invention; 
           [0016]      FIG. 2  illustrates a front view of the radar module attached to the bumper attachment bracket according to the disclosed invention; 
           [0017]      FIG. 3  illustrates a close up view of a portion of the vehicle front bumper assembly of  FIG. 1  but illustrating a bumper extension fitted over a radar module according to the disclosed invention; 
           [0018]      FIG. 4  illustrates a perspective view of the portion shown in  FIG. 3 ; 
           [0019]      FIG. 5  is a front view showing part of the bumper attachment bracket shown without the radar module to illustrate the attachment structures; 
           [0020]      FIG. 6  is an underside view of a portion of the vehicle front bumper assembly of  FIG. 1  illustrating the radar module attached to the bumper attachment bracket; 
           [0021]      FIG. 7  is a graphical illustration of a system for aligning the radar module of the disclosed invention; and 
           [0022]      FIG. 8  is a flow chart illustrating the steps for using the system of  FIG. 7  for aligning the radar module according to the disclosed invention; 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0023]    In the following figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for different constructed embodiments. These specific parameters and components are included as suggested examples and are not meant to be limiting. 
         [0024]    Referring generally to  FIG. 1 , a front perspective view of a vehicle front bumper assembly, generally illustrated as  10 , is shown. The front bumper assembly  10  includes a bumper  12 . It is go be understood that the illustrated shape and configuration of the bumper  12  is shown here for illustrative purposes only and is not intended as being limiting as the disclosed invention may be readily adapted for use with bumpers having other shapes and configurations. 
         [0025]    The bumper  12  is attached to the vehicle (not shown) by a bumper attachment bracket  14  and  14 ′. A portion of the bumper attachment bracket  14  is shown more clearly in  FIG. 2 . The bumper attachment bracket  14  may be formed from one of any of several durable and resilient materials such as high strength steel or from a polymerized material selected from any one of several plastics, fiberglass or nylon, which may or may not be carbon reinforced. As is the case of the bumper itself, the shape and configuration bumper attachment bracket  14  is for illustrative purposes only and is not intended as being limiting as a variety of shapes and configurations may be adapted for use in the disclosed invention. 
         [0026]    Strategically disposed on the bumper attachment bracket  14  is a radar module  16 . An important aspect of the disclosed invention is its adaptability as the radar module  16  may be utilized with either a purpose-designed bumper or with a conventional bumper. In the event that a conventional bumper is used some slight modification may be needed. Particularly, and with reference to  FIG. 1 , the bumper  12  (if “off the shelf”) may require slight modification such as the removal of one or more portions  18  and  18 ′ to accommodate the radar module  16 . 
         [0027]    As illustrated in  FIG. 1 , the radar module  16  is fitted close to the ideal location for effective radar operation. Particularly, according to the disclosed invention, the radar module  16  is fitted high and toward the center of the bumper attachment bracket  14 . It is to be understood that the shape and placement of the radar module  16  are only to be taken as suggestive and non-limiting. 
         [0028]    The radar module  16  preferably consists of one or both of a medium range component beam and a long range radar component. Both of these components may be integrated into a single radar module  16 . Insofar as the typical set-up would have two radar modules mounted in association with the bumper  12  it may be that one radar module includes only a medium range component while the other radar module includes a long range component. 
         [0029]    Regardless of the number or placement of the radar module  16 , it is desirable to provide protection to the radar module  16 . As illustrated in  FIGS. 3 and 4 , a bumper extension  20  is fitted partially or entirely over the radar module  16 . The bumper extension  20  is preferably composed of a polymerized material of a variety of possible types and thus acts as a radome through which radar signals may easily pass. The bumper extension  20  also serves to protect the underlying radar module from protection from water, ice and road debris. The shape, placement and configuration of the bumper extension  20  may be varied from that shown without deviating from the spirit of the invention. 
         [0030]    Attachment of the radar module  16  to the bumper attachment bracket  14  may be made by any one of several methods of attachment. This is best illustrated in  FIGS. 5 and 6 .  FIG. 5  illustrates a front view of the portion of the bumper attachment bracket  14  shown in  FIG. 2  without the radar module  16 .  FIG. 6  illustrates an underside view of a portion of the vehicle front bumper assembly of  FIG. 1  illustrating the radar module  16  attached to the bumper attachment bracket  14 . 
         [0031]    With respect to  FIG. 5 , the bumper attachment bracket  14  includes a radar module-receiving area  22  defined therein for disposition of the radar module  16  (not shown). The footprint defined by the radar module-receiving area  22  is adapted for proper nesting of the radar module  16 . 
         [0032]    The radar module  16  is attached to the radar module-receiving area  22  by mechanical fasteners, such as press-fitted studs  24 ,  24 ′, and  24 ″ of which studs  24 ,  24 ′ and  24 ″ are illustrated in  FIG. 5  and studs  24  and  24 ″ are illustrated in  FIG. 6 . One or more of the studs  24 ,  24 ′ and  24 ″ may function as adjustment screws. A greater or lesser number of studs may be fitted. In addition, other methods of mechanical fastening may be used other than the illustrated press-fitted studs. 
         [0033]    Not shown but understood is the presence of one or more additional holes in the bumper attachment bracket  14  for electrical power connection between the vehicle and the radar module  18 . 
         [0034]    To assure proper operation of the system of the disclosed invention correct installation and alignment are important. Proper installation and alignment of the radar module in the vehicle are important to assure that the module is aligned parallel with the ground to within a defined tolerance. 
         [0035]    According to known installation methods for forward-positioned radar modules, a large precision bracket having a long, rearward-extending alignment arm is used to assure that the radar is aligned with the bracket. According to this arrangement the assembly plant only needs to install the radar module and tighten the fasteners according to a prescribed sequence and the module self-aligns by design. In this process the supplier of the radar module pre-aligns the module to each individual support bracket to account for variation in the radar modules and support brackets. Once attached, the pre-aligned assembly is sent to the vehicle plant. 
         [0036]    The known method, while being satisfactory according to the prior art, is not satisfactory for installation and alignment of the radar module  16  of the front bumper assembly  10  of the disclosed invention. Instead, a new method is needed to support the bumper-integration because a long rear-ward alignment arm previously used is not feasible for use in the disclosed invention. Also it is desired to utilize a bumper attachment bracket  14  that is low cost relative to current designs to which the radar module  16  may be readily attached using the integrated mounting studs  24 ,  24 ′ and  24 ″ described above. 
         [0037]    The disclosed method also removes the supplier from pre-alignment process, thus lowering process steps and improving accuracy. In addition, it is desired to include a process in which each radar module  16  is fitted to the bumper attachment bracket  14  on a case-by-case basis that produces a fit unique to each vehicle rather than the current “one size fits all” approach. This is important particularly for trucks which offer a great variety of body styles, drive trains and option packages and thus vary significantly from unit to unit for ride height and pitch. 
         [0038]    The system for in-plant alignment of the radar module  16  on the vehicle is shown in  FIG. 7 . The system, generally illustrated as  30 , is operated in conjunction with a body-in-white vehicle (BIW)  32  to which at least one radar module  16  has been attached as set forth above. The system  30  includes a first inclinometer  34  and a second inclinometer  36 . The second inclinometer  36  includes a low tolerance bracket  38  having a vertical adjuster (to compensate for uncontrolled vertical bracket variances) and a nut runner  40 . The system  30  is associated with a skillet and posts array  42  to compensate for wear and error. A computer  44  is provided to which components of the system  30  are operatively attached. 
         [0039]    The step-by-step operation of the system  30  is illustrated in  FIG. 8 . At step  1 , the individual radar module  16  is shipped to the vehicle plant alone, that is, without the bumper attachment bracket  14 . At step  2 , the radar module  16  is attached to the bumper attachment bracket  14 . The first electronic inclinometer  34  measures the alignment of the radar module  16  with respect to gravity at step  3 . 
         [0040]    Once the alignment of the radar module  16  with respect to gravity is confirmed at step  3  the second inclinometer  36  measures the vehicle body with respect to gravity to account for variation from vehicle to vehicle at step  4 . The low tolerance bracket  38  compensates for uncontrolled vertical bracket variances. The internal parameters for each radar module  16  are provided on a bar code of the individual radar module  16  which are read by the second inclinometer  36 . 
         [0041]    At step  5  a computer controlling the entire alignment process receives the barcode on the radar module  16  and the results from the first inclinometer  34  in which inclination=+Z and from the second inclinometer  36  in which +Z−S is determined to offset for skillet measurement and squint of the radar module  16  as well as bracket and mount variation. It is possible to add +Y (required radar angle to adapt to various build combinations) to account for vehicle stance per build information if necessary, which may be the case for trucks. 
         [0042]    Based on these findings, at step  6  the computer  44  controls the nut runner  40  which will drive one or more of the studs  24 ,  24 ′ and  24 ″ until the radar module  16  is at the desired set point. 
         [0043]    The disclosed invention provides an effective and practical arrangement for a bumper integrated forward radar mounting system. The system may be incorporated into a bumper design without detracting from styling and structural integrity and with no impact on cooling airflow. On assembly the radar module can be manually adjusted prior to installation of the bumper extension cover. The system of the disclosed invention also helps to reduce assembly and installation cost by eliminating the need for a separate mounting bracket insert for the radar module. In addition, the system of the disclosed invention also can be used by a manufacturer across all vehicle lines without significant variation, thus reducing design costs and eliminating the need for the manufacturer to design each vehicle from scratch. 
         [0044]    The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.