Patent Publication Number: US-9419329-B1

Title: Multi-sensor system and method for vehicles

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     The present application claims the benefit of and priority to and is a Continuation of U.S. application Ser. No. 13/831,035, filed on Mar. 14, 2013, entitled “MULTI-SENSOR SYSTEM AND METHOD FOR VEHICLES” by West et al., which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     The present disclosure relates to a multi-sensor system and method for vehicles, such as aircraft. The electronic equipment often must be at least partially disposed on the outside of the vehicle to accomplish its intended function. 
     Various electronic equipment is utilized on vehicles. The electronic equipment often must be at least partially disposed on the outside of the vehicle to accomplish its intended function. For example, aircraft often include equipment that includes one or more components disposed outside the main fuselage. Such components can include an antenna for an aircraft radar system (such as a weather radar), sensors (e.g., millimeter radars, night vision sensors, targeting sensors, and enhanced vision sensors), antennae for satellite communications (L, Ku, Ka band), air-to-ground communication equipment (3G/4G communication systems), radio antennas, radar altimeters, etc. 
     Generally, radar systems have an antenna that is mechanically steered and disposed outside of the fuselage in a nose cone or radome. Conventional mechanically steered radar antennas often require large sweep volumes that preclude the use of real estate within the radome for other sensors and equipment. The use of space in the enclosed radome volume for other electronic equipment is desirable, especially as more electronic equipment is carried on aircraft. 
     The location of the radar antenna in the radome can also cause issues related to the narrow band of transmissivity associated with the radome. For example, standard air transport system class “sandwich” radomes do not electromagnetically accommodate both X band weather radar and millimeter wave imaging and electro-optical enhanced vision systems. Conventional radome material attenuates electromagnetic energy outside of the X-band range. There is a desire to reduce the volume and weight of the radome. This desire is particularly acute in smaller aircraft, such as, business and regional system (BRS) aircraft and military aircraft. 
     Electronic equipment outside of the aircraft is connected to electronics within the aircraft through holes in the fuselage. For example, the electronic equipment requires that power and data conductors pass through the holes in the fuselage or skin of the aircraft. Providing holes in the fuselage aircraft increases manufacturing costs and can affect the integrity of the fuselage. Further, providing holes in the fuselage requires that the holes be sealed in accordance with requirements for pressurized environments. 
     Thus, there is a need for a system of accommodating multiple sensors on a vehicle, such as an aircraft. Further, there is a need for a multi-sensor system which requires less weight and volume than conventional radome configurations. Further still, there is a need for a method of and system for deploying a weather radar antenna that is not inhibited by transmissiveness characteristics of the radome. There is also a need for a smart nose cone that can be retrofitted onto existing aircraft. Further, there is a need for a housing, such as a nose cone or radome, that includes antennas on its exterior structure for various systems. Further, there is a need for accommodating redundant equipment within the housing upon which antennas are mounted. 
     Accordingly, it would be advantageous to provide a multi-sensor pod that houses a number of electronic components, reduces volume and weight on the vehicle and reduces time required for replacement or repair. 
     SUMMARY 
     An exemplary embodiment relates to a system for a vehicle. The system includes a housing having an exterior surface, and at least two of a radar antenna, a satcom antenna, altimeter antenna, vision sensor, an air-to-ground communication antenna, a communication, navigation and surveillance (CNS) antenna, a directional data link antenna, or a ground-to ground communication antenna mounted on the exterior surface. An interior surface of the housing includes electronics for the at least two of the radar antenna, satcom antenna, altimeter antenna, vision sensor, an air-to-ground communication antenna, or a ground-to ground communication antenna. The housing being a structural component of the vehicle 
     An exemplary embodiment of the disclosure relates to a system for a vehicle. The system including a nose cone housing having and external surface and an internal surface. The system also includes a radar antenna mounted to the external surface of the nose cone housing. The radar antenna can be comprised of a panel. 
     Another exemplary embodiment of the disclosure relates to a system for an aircraft. The system includes a housing having an exterior surface, a weather radar antenna mounted on the exterior surface, and at least one of a Satcom antenna, altimeter antenna, vision sensor or an air-to-ground communication antenna. The weather radar antenna is mounted at a first location on the housing and the at least one of a Satcom antenna, altimeter antenna, vision sensor or an air-to-ground communication antenna is mounted on the exterior surface at a second location. The second location is different than the first location. 
     Another exemplary embodiment of the disclosure relates to a method of providing a first antenna for a first system and a second antenna for a second system for a vehicle. The method includes attaching the first antenna at a first location on an exterior surface of a housing, attaching a second antenna on the exterior surface at a second location, and providing electronics for the first antenna and the second antenna within the housing. The method further includes attaching the housing to an exterior of the vehicle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The exemplary embodiments will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements, and: 
         FIG. 1 a    is a side view of an aircraft with a multi-sensor system in several locations in accordance with exemplary embodiment; 
         FIG. 1 b    is a side view of a military vehicle with a multi-sensor system in several locations in accordance with exemplary embodiment; 
         FIG. 1 c    is a side view of a truck with a multi-sensor system in several locations in accordance with exemplary embodiment; 
         FIG. 1 d    is a fragmentary side view of an aircraft with a multi-sensor system embodied as a nose cone in accordance with exemplary embodiment; 
         FIG. 2  is a general block diagram of the multi-sensor system illustrated in  FIG. 1 d   , including electronic components for the aircraft in accordance with another exemplary embodiment; 
         FIG. 3  is a top view of the multi-sensor system illustrated in  FIG. 1 d    according to another exemplary embodiment; and 
         FIG. 4  is a fragmentary side view of an aircraft with the multi-sensor system illustrated in  FIG. 1 d    including connectors on a bulkhead wall of the aircraft according to yet another exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED AND EXEMPLARY EMBODIMENTS 
     According to one exemplary embodiment, a multi-sensor system can be utilized to provide multiple electronic functions for a vehicle, such as, an aircraft, military vehicle, truck, automobile, etc. the multi-sensor system is provided as part of a structure of the vehicle in one embodiment. The structure includes a housing with an exterior surface and sensor and/or communication components are mounted on an exterior surface of the housing while an interior surface of the housing contains electronics for the components. The housing is a structural member of the vehicle. The housing can be part of an aerodynamic component, a bumper, a door, roof, a hatch, compartment, etc. 
     According to one exemplary embodiment, a multi-sensor system, such as, a smart nose cone, can be utilized to provide multiple electronic functions for a vehicle, such as, an aircraft. The nose cone can be in the shape or form of a radome and can be located at the front of an aircraft in one embodiment. Alternatively, the multi-sensor system can be configured as a multi-sensor suite pod and can be provided at various other exterior portions of a vehicle, such as, at the tail of an aircraft, on a bottom of the aircraft, on wings of the aircraft, etc. The pod can have a conical or non-conical, aerodynamic shape for attachment to various places on the aircraft. 
     Advantageously, the smart nose cone or multi-sensor suite pod provides a low cost multi-sensor fusion system appropriate for various vehicle markets including commercial system and government system aircraft markets. The smart nose cone or multi-sensor suite pod can be used with transport aircraft, military aircraft, business and regional system (BRS) aircraft, private aircraft, helicopters, drones, boats, ships, trains, trucks, automobiles, spacecraft or any vehicle. The smart nose cone or multi-sensor suite pod can advantageously utilize an exterior surface to house various sensor components, such as, antennas, to reduce volume and weight requirements aboard the aircraft for such systems in one embodiment. In addition, the use of a multi-sensor system allows easier retrofitting and requires fewer redundant components than separate conventional systems in one embodiment. Further, the multi-sensor system can advantageously reduce the number of holes in the aircraft fuselage required by electronic equipment in one embodiment. 
     With reference to  FIG. 1 a   , an aircraft  10  includes one or more of multi-sensor systems  20  and  21   a - d . Multi-sensor system  20  and systems  21   a - d  can include a housing, a number of antennas, at least one sensor and electronics. Antennas can be mounted on exterior surface of the housing. An interior surface of the housing can define a cavity for housing electronics associated with the antennas and sensors. Multi-sensor systems  21   a - d  can be similar system  20  discussed below. 
     The housing is provided as a structural member of aircraft  10  in one embodiment. For example, multi-sensor system  20   a  is embodied as a nose cone, and multi-sensor systems  21   a  are provided at locations on a vertical fin  13   a  of aircraft  10 . According to another example, multi-sensor system  20   b  is embodied as a structural member on a wing  13   b  of aircraft  10 , and multi-sensor system  20   c  is embodied as a structural member on the bottom of the fuselage of aircraft  10 . According to another example, multi-sensor system  20   d  is embodied as a door or hatch of aircraft  10 . 
     With reference to  FIG. 1 b   , a military vehicle  11   a  includes one or more of multi-sensor systems  21   e - g . Multi-sensor systems  21   e - g  can include a housing, a number of antennas, at least one sensor and electronics. Antennas can be mounted on exterior surface of the housing. An interior surface of the housing can define a cavity for housing electronics associated with the antennas and sensors. Multi-sensor systems  21   e - g  can be similar system  20  having antennas and sensors for military applications in one embodiment. 
     The housing is provided as a structural member of vehicle  11   a  in one embodiment. For example, multi-sensor system  21   e  is embodied as a hatch, and multi-sensor system  21   g  is embodied as a front portion of vehicle  11   a . According to another example, multi-sensor system  20   f  is embodied as a structural member on a rear portion of vehicle  11   a.    
     With reference to  FIG. 1 c   , a vehicle such as a truck  11   b  includes one or more of multi-sensor systems  21   h - k . Multi-sensor system  20  can include a housing, a number of antennas, at least one sensor and electronics. Antennas can be mounted on exterior surface of the housing. An interior surface of the housing can define a cavity for housing electronics associated with the antennas and sensors. Multi-sensor systems  21   h - k  can be similar system  20  having antennas and sensors for transportation applications in one embodiment. 
     The housing is provided as a structural member of vehicle  11   b  in one embodiment. For example, multi-sensor system  21   i  is embodied as a part of a door, and multi-sensor system  21   h  is embodied as spoiler above the cab of the vehicle  11   b . According to another example, multi-sensor system  20   k  is embodied as a structural member on a top portion of the trailer of vehicle  11   a , and multi-sensor system  21   h  is embodied as bumper of the vehicle  11   b . Alternative structural elements (e.g., hoods, spoilers, mirrors, tailgates, horizontal stabilizers, etc.) and locations associated with aircraft  10 , military vehicle  11   a , truck  11   b  can be used for the multi-sensor systems  21   a - 1  and  20 . 
     With reference to  FIG. 1 d   , aircraft  10  includes multi-sensor system  20  embodied as a smart nose cone. Multi-sensor system  20  can include a housing  21 , antennas  22 ,  24 ,  26  and  27 , at least one sensor  32  and electronics  28 . Antennas  22 ,  24 ,  26  and  27  can be mounted on exterior surface  19  of housing  21 . An interior surface  18  of housing  21  can define a cavity for housing electronics  28 . The cavity can be defined on one end by bulkhead wall  15  of aircraft  10  (e.g., main fuselage of aircraft  10 ). Alternatively, housing  21  can include a wall at bulkhead wall  15  of aircraft  10  and be a completely enclosed housing  19 . 
     Electronics  28  are shown as one block in  FIG. 1 d    but can be multiple components associated with systems for antennas  22 ,  24 ,  26  and  27  and sensor  32 . Electronics  28  can include transmit/receive circuits, power supplies, data communication circuits, modems, interface circuits, computers, memory, processors, etc. Sensor  32  can be any type of sensor useful for a vehicle. Aircraft  10  can include several sensors, such as cameras, targeting sensors, vision sensors, temperature sensors, speed sensors, etc. 
     In one embodiment, electronics  28  can include radio frequency (RF) processing components for the sensor electronics suite associated with system  20 . Electronics  28  can also include optical conversion circuits so that electrical signals from electronics  28  can be converted to optical signals and optical signals can be converted to electric signals for electronics  28  in one embodiment. According to this embodiment, optical data signals as opposed to electronic data signals are provided through the fuselage of aircraft  10 . 
     Advantageously, redundant components can be shared for each of systems associated with antennas  22 ,  24 ,  26  and  27  and sensor  32 . For example, only two redundant power supplies may be required for all of the electronics associated with antennas  22 ,  24 ,  26  and  27  and sensor  32  rather than separate redundant power supplies being required for each as in conventional systems which do not use a multi-sensor configuration. Further, redundant memory, processing circuits, input/output, RF circuits, and data circuits can also be saved by sharing the electronics for the systems associated with antennas  22 ,  24 ,  26  and  27  and sensor  32 . In one embodiment, mechanically steered antenna systems are eliminated from the interior of housing  21 , thereby eliminating the requirement of pressurizing a radome and providing more real estate for electronics  28 . 
     Antenna  22  can be an electronic array scanning antenna for a Satcom system and is generally upwardly disposed on housing  21 . Antenna  24  can be a weather radar antenna for a weather radar and is generally forwardly disposed on a forward portion of housing  21 . Antenna  26  can be for a radar altimeter and antenna  27  can be for a 3G or 4G communication system. Antennas  26  and  27  are generally downwardly disposed on housing  19 . Sensor  32  can also be a vision system sensor, such as, an enhanced vision system sensor. One or more of antennas  22 ,  24 ,  26 , and  27  can be conformally mounted on exterior surface  19  in one embodiment. Sensor  32  can be conformally provided on surface  21  and is disposed for forward viewing. Additional electronic devices such as other sensors can be added to surface  21 . 
     The configuration, arrangement, and operation of multi-sensor systems  20  and  20   a - k  are intended to reduce or minimize the required space and weight, improve performance, expand functionality, and reduce potential failure, malfunction, or normal wear, and reduce repair and assembly time in one embodiment. In one embodiment, components on systems  20  and  21   a - k  can be pre-aligned before final assembly. Each system  20 - 20   a - i  can be entirely completed without the vehicle being present, thereby allowing remote construction of sensor system  10 . 
     Antenna  24  is a panel antenna and can be a low-cost silicon-germanium (SiGe) based active electronically scanned array (“AESA”) antenna in one embodiment. The panel antenna can be a faceted planer AESA panel system with environmentally robust protective super substrate (e.g., Astroquartz). The panel antenna can include two or more faceted silicon-germanium panels in one embodiment. Antenna  24  configured as an electronically steered antenna as opposed to a mechanically steered antenna advantageously eliminates the need for motor and motor drivers, thereby reducing the weight and costs associated with weather radar systems. 
     Antenna  24  can be conformal to the front-conical portion of housing  19 . Pockets can be provided on exterior surface  21  of housing  19  for receiving the panels associated with antenna  24  in one embodiment. 
     According to one embodiment, antenna  24  can be embodied as a conformal electronically scanned array (ESA) structures, or as an ultra-broad band multi-mode esa, such as a balanced anti-podal vivaldi antenna (BAVA). The structure can be configured as a single or double curved surface comprised of piece-wise fragments abutted together to meet aerodynamic requirements in one embodiment. The structure can include a dielectric covering that is environmentally robust. In one embodiment, antenna  24  can be built up during fabrication of housing  19 . 
     According to another embodiment, antenna  24  can be embodied as a dielectric and metallic composition organically grown on surface  21  of housing  19  to provide a structurally integrated antenna similar to antennas used in Dept. of Defense (DOD) applications. Antenna  24  can include high precision and high resolution phase shifters for calibrating non-uniformities out of the radiation aperture in one embodiment. 
     Antenna  24  can be configured for use in multiple frequency band operation, such as for use in high altitude ice sensing applications in one embodiment. Three dimensional synthetic apertures can be obtained by vectoring summation of AESA panels. Frequency Selective Surface (FSS) super substrates and edge treatment for resistive loading can be used to help control radar cross section for low observable applications. 
     Antenna  22  can be an conformal AESA similar to antennas  24 . In one embodiment, antenna  22  can be an ultra light antenna having an aperture from 2 GHz to 18 GHz and can be used for multiple radio systems. 
     Signal distribution paths for bias, control and RF signal distribution can be embedded in the structure of housing  19 . The signal paths can be embodied as photonic lines, RF coaxial strip lines, waveguide conductors, twisted shield pairs, differential high speed digital buses, etc. In this embodiment, housing  19  is no longer an electromagnetic transmissive window which houses a mechanical-based antenna, but rather is a three dimensional aerodynamic mechanical support structure that holds antenna  22 ,  24 ,  26  and  27  as well as sensor system  32  to optimize subsystem functionality. Housing electronics  28  within surface  18  reduces breaches of the fuselage (e.g., a pressurized vessel). 
     Antenna  26  can be a conventional radar altimeter antenna or a panel antenna. Sensor  22  can be conformally applied to a top surface of housing  19  in one embodiment. 
     In one embodiment, antennas  26  and  27  can be similar to antennas  22  and  24  and can be advanced printed array panels implemented in RF printed wiring board technology with environmentally robust super-substrate. Antennas  22 ,  24 ,  26 , and  27  can be disposed in pockets at respective locations on housing  19 . Advantageously, antennas  22 ,  24 ,  26  and  27  can be easily replaced by replacing the antenna into the pocket on housing  19 . 
     Housing  19  can be advantageously retrofitted onto existing aircraft with conventional radomes. Housing  19  can replace a conventional radome and include the additional electronics for a low assembly time and ease of changing of equipment. 
     In one embodiment, multi-sensor system  20  can be configured for particular missions or applications and can be swapped out on a mission by mission basis. For example, certain sensors or certain radars may be required for certain missions, while others are not. Various configurations of system  20  can be utilized so that the appropriate mix of sensors and radars is provided on a number of housings  19 . 
     With reference to  FIG. 2 , housing  19  can include electronics  28  including weather radar electronics  104 , SAT electronics  102 , radar altimeter electronics  106 , ground communication electronics  107 , a first power supply  112 , a second power supply  114 , a first data communication circuit  122  and a second data communication circuit  124 . Electronics for sensor  32  can also be provided in housing  19 . Power supplies  112  and  114  are redundant and can be utilized to power multiple electronics  102 ,  104 ,  106 ,  107 , circuits  122  and  124 , and sensor  32 . Circuits  122  and  124  can also be redundant circuits and can be shared in a similar manner. Additional redundant and non-redundant circuits can also be shared. In one embodiment, common power busses and aircraft interface busses can support a wide range of functions in individual modular suites such as nose cone suites. 
     By providing electronics  28  within housing  19  and sharing power supplies  112  and  114  and data communication circuits  122  and  124 , fewer holes can be required through the bulkhead wall  15 . Various circuits can be hard mounted to the bulkhead wall  15  of aircraft  10 , allowing greater design freedom for thermal management, weight distribution, etc. In certain embodiments, electronics  28  within housing  19  can be combined into a single line replaceable unit. In one embodiment, lengthy fiber optic, RF signal, control, and power line runs along the fuselage of aircraft  10  can be mitigated by placing electronics near bulkhead wall  15 . 
     Antennas for individual functions can be mounted either on the outside of the nose-cone assembly or inside the nose-cone with the mechanical-nose cone being used as an electromagnetic window for the sensor function. Individual sensor alignment or sensor to sensor alignment can be executed at the entire nose-cone module level. Preplanned sensor configurations can be optimized for maximum volume usage without the constraint of aircraft line replaceable unit (LRU) maintenance access. 
     With reference to  FIG. 3 , multi-sensor system  20  is shown detached from aircraft  10 . Weather radar antenna  24  can be configured as two faceted panels at a front end of surface  21  of housing  19 . Each faceted panel includes two sub panels in one embodiment. The panels can be faceted vertically, horizontally, or both vertically and horizontally depending upon geometric criteria. Two panels are used to reduce off-axis scan loss in one embodiment. Antenna  22  is an upward looking antenna for satcom applications, and sensor  32  is a conformal EVS sensor provided on a top portion of surface  21 . System  32  can be provided behind antenna  22  in one embodiment. A radar altimeter or antenna  26  for the radar altimeter can be provided on a bottom portion of surface  21 . Antenna  27  can be provided near antenna  26 . In one embodiment, panels of antenna  24  can be steered independently and operate at different frequencies. A spectrum of multi-beam frequencies and polarizations are possible using antenna  24 . According to an alternative embodiment, antennas for certain individual functions can be mounted inside the nose-cone with the mechanical-nose cone being used as an electromagnetic window. 
     With reference to  FIG. 4 , multi-sensor system  20  is shown detached from bulkhead wall  15  and can include a wall  410  that interfaces with bulkhead wall  15 . Wall  410  can include connectors  404  and  400  disposed to interconnect with connectors  402  and  406  on bulkhead wall  15 . Sensor system  20  can be attached to bulkhead wall  15  by fasteners (e.g., bolts, clamps, rivets, etc.) or adhesives. In one embodiment, wired connectors can extend from electronics  28  and attach to connectors  402  and  406  embodied as fixed connectors on bulkhead wall  15 . Alternatively, connectors  402  and  406  and  404  and  408  can be embodied as wired connectors that can extend from multi-sensor system  20  and bulkhead wall  15 . Although a set of two connectors are shown in an exemplary fashion, any number of connectors can be utilized without departing from the scope of the invention. 
     According to one embodiment, electronics  28  can include an electro-optical converter circuit such that optical signals are provided between aircraft  10  and electronics  28 . The optical signals can be control signals and data signals provided between aircraft  10  and electronics  28 . The optical signals can be provided through optical windows or lenses on wall  410  or bulkhead wall  15 . Alternatively, fiber optic cables and bulkhead connectors can be provided through wall  410  and bulkhead wall  15 . 
     The term “antenna” and “electronics” are intended to be broad terms and not terms of limitation. These components may be used with any of a variety of products or arrangements. For purposes of this disclosure, the term “coupled” shall mean the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. Such joining may also relate to mechanical or electrical relationship between the two components. 
     It is also important to note that the construction and arrangement of the elements of the mounting apparatus as shown in the preferred and other exemplary embodiments are illustrative only. Although only a few embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and/or omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the appended claims.