Patent Publication Number: US-2023135961-A1

Title: Sensor assembly for a vehicle

Description:
BACKGROUND 
     Autonomous vehicles include a variety of sensors. Some sensors detect internal states of the vehicle, for example, wheel speed, wheel orientation, and engine and transmission variables. Some sensors detect the position or orientation of the vehicle, for example, global positioning system (GPS) sensors; accelerometers such as piezo-electric or microelectromechanical systems (MEMS); gyroscopes such as rate, ring laser, or fiber-optic gyroscopes; inertial measurements units (IMU); and magnetometers. Some sensors detect the external world, for example, radar sensors, scanning laser range finders, light detection and ranging (lidar) devices, and image processing sensors such as cameras. A lidar device detects distances to objects by emitting laser pulses and measuring the time of flight for the pulse to travel to the object and back. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of an example vehicle including a plurality of sensor assemblies. 
         FIG.  2    is a perspective view of an example bracket for attaching the sensor assembly to a body of the vehicle. 
         FIG.  3    is a frontal view of the sensor assembly shown in  FIG.  1   . 
         FIG.  4 A  is a frontal view of the sensor assembly with a sensor cover removed from the sensor assembly. 
         FIG.  4 B  is a frontal view of the sensor assembly with an air nozzle cover removed from the sensor assembly. 
         FIG.  5    is an exploded view of the sensor assembly of  FIG.  3   . 
         FIG.  6    is a cross-sectional view of the sensor assembly of  FIG.  3   . 
     
    
    
     DETAILED DESCRIPTION 
     A sensor assembly includes a first sensing device and a second sensing device spaced from the first sensing device. The sensor assembly includes a bracket supporting the first sensing device and the second sensing device. The sensor assembly includes a sensor cover including a first sensor window and a second sensor window. The first sensing device has a first field of view through the first sensor window and the second sensing device has a second field of view through the second sensor window. The sensor assembly includes an air nozzle housing supported by the bracket. The air nozzle housing defines a first air nozzle aimed toward the first sensor window and a second air nozzle aimed toward the second sensor window. The sensor assembly includes a washer nozzle spaced from the first air nozzle, the washer nozzle aimed toward the first sensor window in a direction opposite to a direction of the first air nozzle. 
     The direction at which the washer nozzle may be aimed is downwardly toward the first sensor window and the direction at which the first air nozzle is aimed is upwardly toward the first sensor window. 
     The washer nozzle may be spaced upwardly from the first air nozzle. 
     The sensor assembly may include a second washer nozzle spaced from the washer nozzle, the second washer nozzle aimed toward the second sensor window. 
     The first air nozzle may be aimed in a direction opposite a direction of the second air nozzle. 
     The washer nozzle and the first air nozzle may be vehicle-outboard of the bracket. 
     The sensor assembly may include an air inlet fluidly connected to the first air nozzle and the second air nozzle. 
     The sensor assembly may include a blower positioned to receive airflow from the air inlet and to blow the airflow into the first air nozzle and the second air nozzle. 
     The air nozzle housing may define a duct extending from the blower to the first air nozzle and the second air nozzle. 
     The air inlet, the first air nozzle and the second air nozzle, the blower, and the duct may define a flow path extending from the air inlet to the first air nozzle and the second air nozzle. 
     The bracket may be a single piece. 
     The bracket may be supportable by a vehicle body. 
     The first sensing device may be a camera and the first sensor window includes a lens. 
     The second sensing device may be a lidar sensing device. 
     The second sensing device may be cylindrical and elongated along an axis, the second air nozzle extending around the axis along the second sensing device. 
     The air nozzle housing may include an air nozzle cover extending at least partially around the axis, the air nozzle cover including the first air nozzle. 
     The air nozzle cover includes a scoop spaced from the axis and aimed toward the first sensor window. 
     The second sensing device may extend downwardly from the bracket. 
     The first sensing device may be positioned on an opposite side of the bracket from the first sensing device. 
     With reference to the Figures, wherein like numerals indicate like parts throughout the several views, a sensor assembly  10  for a vehicle  12  includes a first sensing device  14  and a second sensing device  16  spaced from the first sensing device  14 . The sensor assembly  10  includes a bracket  18  supporting the first sensing device  14  and the second sensing device  16  and a sensor cover  20  including a first sensor window  22  and a second sensor window  24 . The sensing devices  14 ,  16  can include devices such as optical cameras, lidar, radar, etc. The first sensing device  14  has a first field of view through the first sensor window  22  and the second sensing device  16  having a second field of view through the second sensor window  24 . The sensor assembly  10  includes an air nozzle housing  26  supported by the bracket  18 . The air nozzle housing  26  defines a first air nozzle  28  aimed toward the first sensor window  22  and a second air nozzle  30  aimed toward the second sensor window  24 . The sensor assembly  10  includes a washer nozzle  32  spaced from the first air nozzle  28 . The washer nozzle  32  is aimed toward the first sensor window  22  in a direction opposite a direction of the first air nozzle  28 . 
     The air nozzles  28 ,  30  and the washer nozzle  32  can be used to clear debris from the sensing devices  14 ,  16  after debris comes into contract with the sensing devices  14 ,  16 . The air nozzles  28 ,  30  can limit the amount of debris that contact with the sensing devices  14 ,  16 , and the washer nozzles  32 ,  44  can remove at least some debris that is not removed by the air nozzles  28 ,  30 . The first air nozzle  28  and the washer nozzle  32  aimed in a direction opposite the direction in which the first air nozzle  28  is aimed advantageously to allow the first sensing device  14  to be packaged and assembled above the second sensing device  16 . Advantageously, having the first air nozzle  28  aimed in a direction opposite the direction of the washer nozzle  32  allows for installation of the first sensing device  14  during manufacturing and assembly of the sensor assembly  10  and a vehicle  12 . For example, the first air nozzle  28  being on an opposite side of the first sensing device  14  from the washer nozzle  32  can allow for the first sensing device  14  to be installed above the air nozzle housing  26  to provide installation space for connectors of the first sensing device  14  to extend from a backside of the first sensing device  14 . This placement of the first sensing device  14  allows for air to move below the first sensing device  14  and upward from the first air nozzle  28  and toward the first sensing device  14 . The locations of the first air nozzle  28  and the washer nozzle  32  allow for airflow to reach the first sensing device  14  to provide cleaning as described above, and further provide for assembly of the sensor assembly  10 . 
     With reference to  FIG.  1   , the vehicle  12  may be any suitable type of automobile, e.g., a passenger or commercial automobile such as a sedan, a coupe, a truck, a sport utility vehicle, a crossover vehicle, a van, a minivan, a taxi, a bus, etc. The vehicle  12 , for example, may be an autonomous vehicle. In other words, the vehicle  12  may be autonomously operated such that the vehicle  12  may be driven without constant attention from a driver, i.e., the vehicle  12  may be self-driving without human input, e.g., based on data received from the first sensing device  14 , the second sensor, and the third sensing device. 
     With reference to  FIGS.  1  and  2   , the vehicle  12  includes a body  34 . The vehicle  12  may be of a unibody construction, in which a frame and the body  34  of the vehicle  12  are a single component. The vehicle  12  may, alternatively, be of a body-on-frame construction, in which the frame supports the body  34  that is a separate component from the frame. The frame and body  34  may be formed of any suitable material, for example, steel, aluminum, etc. The body  34  includes body  34  panels partially defining an exterior of the vehicle  12 . The body  34  panels may present a class-A surface, e.g., a finished surface exposed to view by a customer and free of unaesthetic blemishes and defects. 
     With continued reference to  FIGS.  1  and  2   , the sensor assembly  10  is supported by the body  34  of the vehicle  12 . Specifically, the sensor assembly  10  includes the bracket  18  and the bracket  18  is supportable by the body  34  of the vehicle  12 , i.e., the sides of the vehicle  12 . For example, the sensor assembly  10  may be disposed on a front end of the vehicle  12  below a beltline of the vehicle  12 , as shown in  FIG.  1   . While the description herein may refer to a single sensor assembly  10 , as illustrated in  FIG.  1   , the vehicle  12  may include multiple sensor assemblies  10 , each disposed at a different locations on the vehicle  12 , i.e., different locations on the body  34 . The sensor assemblies  10  may be arranged to provide the sensing devices  14 ,  16  with a collective or combined field of view entirely around a front end of the vehicle  12 , for example. 
     In addition to the sensor assemblies  10  along the sides of the vehicle  12 , the vehicle  12  may include a rooftop sensor assembly  48  supported by the roof  50  of the vehicle  12 . The rooftop sensor assembly  48  may include sensing devices (not numbered) for a field of view around the vehicle  12  from the roof  50  of the vehicle  12 . The rooftop sensor assembly  48  may operate in combination with the sensor assemblies  10  around the vehicle  12  to provide a collective or combined field of view entirely around the vehicle  12 , for example. 
     As discussed above, the bracket  18  is supported by the body  34  of the vehicle  12  e.g., bolted to the body  34  of the vehicle  12  or mounted in any suitable way, and is thereby fixed relative to the sensor cover  20 . The bracket  18  may extend in an outward direction (sometimes referred to as vehicle-outboard) from the body  34  of the vehicle  12 . The bracket  18  is a single or unitary part, i.e., made of a single, uniform piece of material with no seams, joints, fasteners, or adhesives holding it together. 
     With reference to  FIGS.  3 - 6   , the sensor assembly  10  includes one or more sensing devices  14 ,  16  supported by the bracket  18 . In the example shown in the Figures, the sensor assembly  10  includes the first sensing device  14  and the second sensing device  16 . 
     The first sensing device  14  and the second sensing device  16  are each supported by the bracket  18 . The bracket  18  fixes the position of the sensing device relative to the sensor cover  20 , including relative to the bracket  18 . For example, the sensing devices  14 ,  16  may be press-fitted into an opening through the bracket  18  and/or may be fixed by fasteners, e.g., screws, bolts, etc. The sensing devices  14 ,  16  may be directly supported by the bracket  18  or indirectly supported by the bracket  18 . In the present context, directly means that no other vehicle components are between the sensing devices  14 ,  16  and the bracket  18 ; indirectly means that other vehicle components may be between the sensing devices  14 ,  16  and the bracket  18 . For example, the first sensing device  14  is indirectly supported by the bracket  18  by the air nozzle housing  26  and the second sensing device  16  is directly supported by the bracket  18  by being press-fitted into the opening in the bracket  18 . 
     The first sensing device  14  and the second sensing device  16  are spaced from each other. When the sensor assembly  10  is in an orientation in which it is or will be installed on a vehicle  12 , the first sensing device  14  may be spaced upwardly from the second sensing device  16  relative to the bracket  18  of the senor assembly  10 . The first sensing device  14  may be positioned on an opposite side of the bracket  18  from the first sensing device  14 , i.e., the first sensing device  14  may be upward of the bracket  18  and the second sensing device  16  may be downward from the bracket  18 . 
     The sensing devices  14 ,  16  detect the external world, e.g., objects and/or characteristics of surroundings of the vehicle  12 , such as other vehicles  12 , road lane markings, traffic lights and/or signs, pedestrians, etc. For example, the sensing devices  14 ,  16  can be radar sensors, scanning laser range finders, light detection and ranging (lidar) sensing devices, or an image processing sensor such as a camera. In one example, the first sensing device  14  is a camera and the second sensing device  16  is a lidar sensing device. 
     In such examples where the first sensing device  14  is a camera, the first sensor window  22  may include a lens  46 . In other words, the first field of view through the first sensor window  22  is through the lens  46  of the camera. 
     The lidar sensing device is similar to radar but uses laser light transmissions instead of radio transmissions to obtain reflected light pulses from objects. The reflected light pulses can be measured to determine object distances. Data from a lidar can be provided to generate a three-dimension representation of detected objects, sometimes referred to as a point cloud. 
     In such examples where the second sensing device  16  is a lidar sensing device, the second sensing device  16  may be cylindrical. The second sensing device  16  extends downwardly from the bracket  18  and may be elongated along an axis A. 
     With reference to  FIGS.  3 ,  5 , and  6   , the sensor assembly  10  includes the sensor cover  20 . The sensor cover  20  may have a class-A surface, i.e., the sensor cover  20  may be a finished surface exposed to view by a customer and free of unaesthetic blemishes and defects. The sensor cover  20  may be disposed over other components of the sensor assembly  10 , e.g., the bracket  18  and the sensing devices  14 ,  16 . The bracket  18  and other components of the sensor assembly  10  may be between the sensor cover  20  and the body  34  of the vehicle  12 . The sensing devices  14 ,  16  may be between the sensor cover  20  and the bracket  18 . 
     The sensor cover  20  includes the first sensor window  22  and the second sensor window  24 . The sensing devices  14 ,  16  may be positioned to have fields of view through the sensor windows  22 ,  24 . The first sensing device  14  can have a first field of view through the first sensor window  22  and the second sensing device  16  has a second field of view through the second sensor window  24 . The sensing devices  14 ,  16  may detect the external world through the fields of view. 
     With reference to  FIGS.  4 A and  4 B , the sensor assembly  10  includes the air nozzle housing  26  supported by the bracket  18 . The air nozzle housing  26  may be supported on an opposite side of the bracket  18  from the second sensing device  16 , i.e., in an installation orientation of the sensor assembly  10 , the air nozzle housing  26  may be above the bracket  18  and the second sensing device  16  may be below the bracket  18 . The air nozzle housing  26  may be supported on the same side of the bracket  18  as the first sensing device  14 . The air nozzle housing  26  may be, such as in the example shown in the Figures, supported by the bracket  18  between the first sensing device  14  and the bracket  18 . In other words, the first sensing device  14  may be supported by the air nozzle housing  26 . 
     The air nozzle housing  26  may define air nozzles  28 ,  30  aimed toward the sensor windows  22 ,  24 . The air nozzles  28 ,  30  allow air to pass across the sensor windows  22 ,  24  and the sensing devices  14 ,  16  to block debris, e.g., insects, dust, pollen, dirt, rain, etc., from landing on the sensor windows  22 ,  24 , whereby the debris can at least partly block the fields of view. The air nozzles  28 ,  30  may act as a shield or “curtain” to block debris that otherwise could land on or contact the sensor windows  22 ,  24 . The air nozzle housing  26  may define a duct to allow air to move through the air nozzle housing  26  and through the sensor windows  22 ,  24 . The air nozzle housing  26  may define a first air nozzle  28  aimed toward the first sensor window  22  and a second air nozzle  30  aimed toward the second sensor window  24 . Because the first sensing device  14  and the second sensing device  16  are spaced from each other and on opposite sides of the bracket  18 , the first air nozzle  28  is aimed in a direction opposite a direction of the second air nozzle  30 . In other words, as shown in the example in the Figures, the first air nozzle  28  may be aimed upwardly at the first sensing device  14  and first sensor window  22 , and the second air nozzle  30  may be aimed downwardly at the second sensing device  16  and the second sensor window  24 . The first air nozzle  28  can then direct air in a direction away from the direction of the second air nozzle  30 , i.e., the first air nozzle  28  directs air at the first sensor window  22  to prevent and remove debris from the first sensor window  22  and the second air nozzle  30  directs air at the second sensor window  24  to prevent accumulation of, and/or remove, debris from the second sensor window  24 . 
     The first air nozzle  28  may be positioned at a forward portion of the air nozzle housing  26 , directly below the first sensor window  22 . The first air nozzle  28  allows air to pass across the first sensor window  22  and first sensing device  14 . In other words, the air from the first air nozzle  28  passes from one side of the first sensor window  22  to the other side of the first sensor window  22 , generally along a plane defined by or parallel to a plane defined by the first sensor window  22 . The first air nozzle  28  may move air across the first sensor window  22  and the first sensing device  14  to remove debris or prevent debris from reaching the first sensor window  22 . The air nozzle housing  26  may include an air nozzle cover  36  extending at least partially around the axis A along which the second sensing device  16  is elongated. The air nozzle cover  36  may extend around the front portion of the sensor assembly  10  and the second sensing device  16 . 
     The air nozzle cover  36  may include the first air nozzle  28  aimed toward the first sensor window  22 . As shown in the example in the Figures, the air nozzle cover  36  may include a scoop  38  spaced from the axis A. The scoop  38  may be aimed toward the first sensor window  22 . The scoop  38  may protrude from the front of the sensor assembly  10  to direct air toward the first sensor window  22 . 
     The second air nozzle  30  may extend around the axis A and along the second sensing device  16 . In other words, the second air nozzle  30  may extend around the axis A and along an upper edge of the second sensing device  16 . The second air nozzle  30  may have a semi-circular shape extending around the upper edge of the second sensing device  16 . The second air nozzle  30  may prevent debris from reaching the second sensing device  16 . The second air nozzle  30  may extend around the cylindrical second sensing device  16  and direct air across the second sensor window  24  and the second sensing device  16 . In other words, the second air nozzle  30  directs air downward across the second sensing device  16 , i.e., from the upper edge of the second sensing device  16  and downwardly relative to the bracket  18 . 
     The sensor assembly  10  includes an air inlet  40  fluidly connected to the first air nozzle  28  and the second air nozzle  30 . The air inlet  40  draws in air from an exterior of the vehicle  12  and the sensor assembly  10  to move air through the first air nozzle  28  and the second air nozzles  30 . In other words, the air inlet  40  intakes air from outside of the vehicle  12  and the sensor assembly  10  to move through the air nozzles  28 ,  30 . The air inlet  40  may be below the second sensing device  16 . The air is drawn into the sensor assembly  10  through the air inlet  40  from the exterior of the vehicle  12  and the sensor assembly  10 . The air moves upward into the sensor assembly  10  to move the air through the air nozzles  28 ,  30 . 
     With reference to  FIGS.  3  and  6   , the sensor assembly  10  may include a blower  42  between the air inlet  40  and the air nozzles  28 ,  30  to move air from the exterior of the vehicle  12 , through the air nozzles  28 ,  30 , and toward the sensor windows  22 ,  24  of the sensing devices  14 ,  16 . The blower  42  is supported by the bracket  18  of the sensor assembly  10 . The blower  42  is positioned to receive airflow from the air inlet  40  and to blow the airflow into the air nozzles  28 ,  30 . The duct of the air nozzle housing  26  may extend from the blower  42  to the air nozzles  28 ,  30 . The air inlet  40 , the air nozzles  28 ,  30 , the blower  42 , and the duct define a flow path extending from the air inlet  40  to the air nozzles  28 ,  30 . The flow path may be evidenced by the arrows shown in  FIG.  6    showing the direction of airflow through the sensor assembly  10 . In other words, air may flow from the exterior of the vehicle  12 , through the air inlet  40 , through the blower  42 , through the duct, and out the air nozzles  28 ,  30  toward the sensor windows  22 ,  24 . 
     The sensor assembly  10  includes one or more washer nozzles  32 ,  44  aimed at the sensor windows  22 ,  24 . The washer nozzles  32 ,  44  may be connected to washer fluid from the vehicle  12 . The washer nozzles  32 ,  44  are used to clean debris that may be blocking the fields of view of the sensing device. In the example shown in the Figures, the sensor assembly  10  includes a first washer nozzle  32  aimed toward the first sensing device  14  and the first sensor window  22  and at least one second washer nozzle  44  aimed toward the second sensing device  16  and the second sensor window  24 . As shown in the Figures, the sensor assembly  10  may include a plurality of second washer nozzles  44  aimed toward the second sensor window  24 . 
     The first washer nozzle  32  and the first air nozzle  28  are vehicle-outboard of the bracket  18 . In other words, the first washer nozzle  32  and the first air nozzle  28  may be on the front side of the sensor assembly  10 , i.e., vehicle-outboard of the bracket  18 . The first washer nozzle  32  is spaced upwardly from the first air nozzle  28 . In other words, the first washer nozzle  32  is on an opposite side of the first sensing device  14  and first sensor window  22  from the first air nozzle  28 . The first washing device may be above the first sensing device  14  and the first air nozzle  28  may be below the first sensing device  14 . Because the first washing device and the first air nozzle  28  are on opposite sides of the first sensing device  14  and first sensor window  22 , the first washer nozzle  32  is aimed toward the first sensor window  22  in a direction opposite the direction of the first air nozzle  28 . In other words, the first washer nozzle  32  directs washer fluid at the first sensor window  22  and the first air nozzle  28  directs air at the first sensor window  22  in the direction opposite the direction of the first washer nozzle  32 . As shown in the Figures, when the sensor assembly  10  is in an installation orientation, the first washer nozzle  32  is aimed downwardly relative to the first sensor window  22  and the first air nozzle  28  is aimed upwardly relative to the first sensor window  22 . The first washer nozzle  32  and the first air nozzle  28  operate in combination with each other to prevent debris and remove debris from the field of view of the first sensing device  14 . The first air nozzle  28  and the washer nozzle aimed in a direction opposite to the direction of the first air nozzle  28  allows for the first sensing device  14  to be packaged and assembled above the second sensing device  16 . The locations of the first air nozzle  28  and the washer nozzle allow for adequate airflow to reach the first sensing device  14  and for assembly of the sensor assembly  10 . 
     The adjectives “first” and “second” are used throughout this document as identifiers for the sensing devices  14 ,  16 , sensor windows  22 ,  24 , air nozzles  28 ,  30 , and washer nozzles  32 ,  44  and, unless explicitly stated otherwise, are not intended to signify importance, order, or quantity. 
     The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.