WO2020210450A1 - Vehicle camera and sensor washer manifold with freeze robustness - Google Patents

Vehicle camera and sensor washer manifold with freeze robustness Download PDF

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Publication number
WO2020210450A1
WO2020210450A1 PCT/US2020/027410 US2020027410W WO2020210450A1 WO 2020210450 A1 WO2020210450 A1 WO 2020210450A1 US 2020027410 W US2020027410 W US 2020027410W WO 2020210450 A1 WO2020210450 A1 WO 2020210450A1
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WO
WIPO (PCT)
Prior art keywords
fluid
manifold assembly
body portion
passage
injector
Prior art date
Application number
PCT/US2020/027410
Other languages
French (fr)
Inventor
Douglas Edward Cosby
Michael J Hornby
Stephen C BUGOS
Perry Robert Czimmek
Original Assignee
Vitesco Technologies USA, LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vitesco Technologies USA, LLC filed Critical Vitesco Technologies USA, LLC
Publication of WO2020210450A1 publication Critical patent/WO2020210450A1/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16KVALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K27/00Construction of housing; Use of materials therefor
    • F16K27/003Housing formed from a plurality of the same valve elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60SSERVICING, CLEANING, REPAIRING, SUPPORTING, LIFTING, OR MANOEUVRING OF VEHICLES, NOT OTHERWISE PROVIDED FOR
    • B60S1/00Cleaning of vehicles
    • B60S1/02Cleaning windscreens, windows or optical devices
    • B60S1/46Cleaning windscreens, windows or optical devices using liquid; Windscreen washers
    • B60S1/48Liquid supply therefor
    • B60S1/481Liquid supply therefor the operation of at least part of the liquid supply being controlled by electric means

Definitions

  • the present invention relates to a washing system, and particularly to a manifold assembly for use in washing cameras and other sensors having lenses mounted to the exterior of a motor vehicle.
  • Example embodiments overcome shortcomings associated with the use of cameras and sensors mounted along vehicle exteriors and thereby satisfy a need for a cleaning system for externally mounted cameras and sensors.
  • a manifold assembly for washing cameras or sensors of an autonomous vehicle including a fluid inlet, a fluid passage in fluid communication with the fluid inlet, and one or more fluid outlets.
  • the manifold assembly includes a plurality of fluid injectors, each of which is disposed at least partly within the manifold assembly between the fluid passage and a fluid outlet.
  • the fluid passage and the fluid injectors form a plurality of fluid paths in the manifold assembly.
  • the fluid passage widens from the fluid inlet to an end portion of the manifold assembly opposite the fluid inlet.
  • a diameter of the fluid passage may gradually increase from the fluid inlet.
  • the diameter of the fluid passage gradually decreases from the fluid inlet for a predetermined distance, and gradually increases from the predetermined distance to the end portion of the manifold assembly opposite the fluid inlet.
  • the manifold assembly includes a volume expansion assembly in fluid communication with the fluid passage.
  • An end cap connected to an end portion of the manifold assembly is disposed opposite the fluid inlet.
  • the volume expansion assembly increases a volume of the fluid passage responsive to expansion forces from fluid in the inner bore freezing.
  • the volume expansion assembly includes a plunger member moveably disposed in the in the fluid passage, and a spring member disposed within the inner bore between the end cap and the plunger member.
  • the manifold assembly may include an inner wall which defines the fluid passage, the inner wall including a shoulder which extends radially inwardly.
  • the plunger member is disposed between the end cap and the shoulder, the shoulder serving as a stop for the plunger member.
  • the spring member is configured to provide a spring force to the plunger member that is greater than fluid pressure of fluid in the fluid passage during normal operation of the manifold assembly, and less than an expansion force of the fluid when the fluid freezes.
  • the volume expansion assembly includes a collapsible bladder having a resiliently compressible gas disposed therein.
  • the collapsible bladder is disposed at the end portion of the fluid passage opposite the fluid inlet.
  • the collapsible bladder may be constructed from a rubber composition.
  • the collapsible bladder may be fully contained within the fluid passage.
  • the manifold assembly may include a first body portion in which the fluid passage and at least part of the fluid inlet are defined, with an upstream portion of each injector being disposed in the first body portion. A downstream portion of each injector is disposed in a second body portion.
  • Each of the first body portion and the second body portion includes a through-bore, each through-bore of the first body portion being located so as to align with a corresponding through-bore of the second body portion.
  • the first and second body portions are aligned with each other and secured together by fastening each through-bore of the first body portion with the corresponding through-bore of the second body portion.
  • the one or more fluid outlets includes a plurality of fluid outlets, with each fluid outlet being associated with at least one fluid injector.
  • the one or more fluid outlets includes a single fluid outlet, and the plurality of fluid paths are in fluid communication with the single fluid outlet.
  • a manifold assembly for washing camera and sensors of an autonomous vehicle includes a fluid inlet and a fluid passage in fluid
  • the manifold assembly further includes a plurality of fluid injectors, each fluid injector disposed at least partly within the manifold assembly in fluid communication with the fluid passage. At least one fluid outlet is in fluid communication with a fluid output of at least two of the fluid injectors. The at least one fluid outlet may be a single fluid outlet.
  • each fluid injector includes a control input interface which receives one or more control signals for controlling the fluid injector, wherein each fluid injector is configured to be separately controllable.
  • the manifold assembly includes a first body portion in which the fluid passage and at least part of the fluid inlet are defined, an upstream portion of each injector being disposed in the first body portion.
  • the manifold assembly also includes s second body portion in which a downstream portion of each injector is disposed.
  • Each of the first body portion and the second body portion includes a through-bore, each through-bore of the first body portion being located so as to align with a corresponding through-bore of the second body portion.
  • the first and second body portions are aligned with each other and secured together by fastening each through-bore of the first body portion with the corresponding through-bore of the second body portion.
  • the fluid passage gradually widens in a direction away from the fluid inlet.
  • a first retaining member is disposed within the second body portion downstream, relative to a flow of fluid through the manifold assembly, of a fluid output of a first injector of the plurality of injectors.
  • the first retaining member has a radially outward facing recess.
  • a seal member is disposed in the recess and contacts an inner surface of the second body portion. The seal member provides a seal between the second body member, the first retaining member and the first injector.
  • FIG. 1 is a cross sectional side view of manifold assembly of a vehicle
  • cam era/ sensor washing system according to an example embodiment
  • FIG. 2 is a partial cross sectional side view of the manifold assembly of Fig. 1 illustrating a fluid distribution passage
  • FIG. 3 is a partial cross sectional side view of the manifold assembly of Fig. 1 illustrating a volume expansion assembly thereof according to an example embodiment
  • Fig. 4 is an exterior side view of the manifold assembly of Fig. 1;
  • FIG. 5 is a simplified view of the partial cross sectional view of Fig. 3;
  • FIGs. 6 and 7 are simplified cross sectional views of the volume expansion assembly of the manifold assembly according to another example embodiment
  • FIGs. 8 and 9 illustrate cross sectional views of a body portion of the manifold assembly according to additional example embodiments
  • Fig. 10 is a cross sectional view of a manifold assembly according to another example embodiment.
  • Figs. 11 and 12 illustrate side and bottom elevational views, respectively, of the manifold assembly of Fig. 10.
  • example embodiments of the present disclosure are directed to a manifold assembly of a wash systems for camera and sensors of autonomous vehicles.
  • the manifold assembly is disposed within the vehicle and in fluid communication between a source of washing fluid and exit ports of the wash system which discharge the washing fluid towards a plurality of the vehicle’s cameras and sensors.
  • the manifold assembly serves to provide and distribute washing fluid to the externally-facing cameras and sensors of a motor vehicle.
  • Figs. 1-5 there is shown a manifold assembly 10 according to an example embodiment.
  • Manifold assembly 10 is configured to be part of a camera/sensor wash system for a motor vehicle, between a source of washing fluid and the exit ports of the wash system, and particularly between a fluid pump on an upstream side and the exit ports on a downstream side of the manifold assembly 10.
  • Manifold assembly 10 includes an inlet 50 disposed at one longitudinal end of the assembly and configured to receive, either directly or indirectly, fluid from a source of washing fluid to be used to wash exterior-facing cameras and sensors of a motor vehicle, such as the cameras and sensors which provide autonomous control functionality.
  • Manifold assembly 10 further includes a plurality of outlets 52 which selectively provide washing fluid received at inlet 50.
  • manifold assembly 10 includes a first body portion
  • First body portion 12 forms the upper part of the manifold and second body portion 14 forms the lower part thereof.
  • First body portion 12 and second body portion 14 may each include a plurality of through-bores 70, with a through-bore 70 of first body portion 12 being aligned with a corresponding through-bore 70 of second body portion 14.
  • the first and second body portions may be secured together using a bolt extending through each through-bore 70 and held in place with a nut (not shown).
  • One or more through-bores 70 may also be used for mounting manifold assembly 10 within the vehicle.
  • Manifold assembly 10 includes valves for selectively controlling the flow of fluid from fluid inlet 50 to fluid outlets 52.
  • the valves are fluid injectors 20, and in particular are fuel injectors.
  • first body portion 12 and second body portion 14 define a plurality of spaces when the body portions are coupled together, with each space being sized for receiving an injector 20 therein.
  • Injectors 20 are arranged such that each injector 20 selectively passes fluid from inlet 50 to a distinct fluid outlet 52.
  • each injector 20 is a conventional fuel injector and includes components typically found in a fuel injector, including an actuator unit having a coil, a stationary pole piece, a moveable armature which moves in response to an electromagnetic force generated from passing a current through the coil, and a spring which biases the armature; a valve assembly including a valve seat and a valve needle which is coupled to the armature for at least partial movement therewith.
  • the valve seat engages with an end of the valve needle when the valve assembly is in the closed position and is spaced from the valve seat when the valve assembly is in the open position.
  • each injector 20 includes a first seal member disposed at or near a fluid input of the injector, and a second seal member disposed at or near a fluid output of the injector.
  • Each such seal member may be a compressible O-ring.
  • the O-rings provide a seal between the injector 20 and the first and second body portions so as to prevent fluid from flowing around the exterior of injectors 20.
  • the electrical control interface of each injector 20 extends from first body portion 12 and second body 14 of manifold assembly 10 so as to provide easy connection to a controller or like device.
  • injectors 20 are independently controlled by a controller of the vehicle (not shown). In this way, the camera/sensor washing system is able to independently and separately wash each camera/sensor as needed.
  • first body portion 12 includes an inner bore or primary passage 40 and a plurality of secondary passages 60 which are configured to provide a fluid path from inlet 50 to the fluid input of each injector 20.
  • Passage 40 extends from inlet 50 to an opposite (longitudinal) end portion of manifold assembly 10.
  • Each secondary passage 60 provides fluid communication from primary passage 40 to the fluid input of a distinct injector 20.
  • primary passage 40 gradually widens from inlet 50 at one longitudinal end portion of manifold assembly 10 to the opposite longitudinal end portion thereof.
  • primary passage 40 gradually widens such that the diameter D1 of passage 40 at the longitudinal end portion of manifold assembly 10 opposite inlet 50 is between 102% and 130% greater than the diameter D2 of primary passage 40 at inlet 50, and particularly between 115% and 125%, such as 120%.
  • a widening primary passage 40 advantageously causes or at least allows for frozen portions of fluid within passage 40 to move along passage 40 in a direction of the widening of passage 40, i.e., in a direction away from fluid inlet 50.
  • primary passage 40 widens from inlet 50 in a non- gradual progression, such as in a step-wise manner.
  • Manifold assembly 10 further includes a volume expansion assembly 30 disposed in a longitudinal end portion that is opposite inlet 50.
  • volume expansion assembly 30 includes an end cap 300 which is sealingly engaged at the longitudinal end of primary passage 40.
  • a plunger 310 is movably disposed within primary passage 40 between a radially inwardly extending shoulder 40A of primary passage 40 and the longitudinal end of the passage.
  • An O-ring 320 or other seal member is disposed circumferentially around plunger 310 so as to provide a seal between plunger 310 and primary passage 40.
  • Volume expansion assembly 30 further includes a spring 330 disposed in the space between plunger 310 and end cap 300 which biases plunger 310 in a direction towards shoulder 40A and inlet 50.
  • spring 330 includes a first end which contacts end cap 300 and a second end which contacts plunger 310.
  • Spring 330 is configured so that plunger 310 is positioned against shoulder 40A when spring 330 is in its most uncompressed state during normal operation of manifold assembly 10 in which the fluid in passage 40 is under pressure. Spring 330 is only compressed due to movement of plunger 310 towards end cap 300 from fluid expansion forces when the washing fluid in passage 40 freezes.
  • washing fluid is provided under pressure to primary passage 40 of manifold assembly 10.
  • a controller (not shown) in the vehicle determines that a camera or sensor of the vehicle needs to be washed
  • the controller transmits a control signal to activate or open an injector 20 corresponding to camera/sensor needing to be washed. It is understood that more than one injector may be activated at a time.
  • the control signal is received by the selected injector 20 which energizes the coil in the injector 20 so as to cause the armature to move and displace the valve needle from the valve seat of injector 20, thereby opening the injector.
  • Injector 20 being opened allows the pressurized washing fluid in passage 40 to pass through the injector and exit manifold assembly 10 via the outlet 52 corresponding to the activated injector.
  • the pressure in passage 40 and passage 60 is such that plunger 310 is urged by spring 330 against shoulder 40A of passage 40.
  • the spring force provided by spring 330 is greater than the forces associated with the pressurized washing fluid in passage 40.
  • the fluid in passage 40 may freeze.
  • the diametrically expanding frozen portions move in passage 40 in a direction of the widening passage (i.e., away from fluid inlet 50), and may eventually expand to such an extent that the frozen fluid presents an expansion force on plunger 310 in a direction towards end cap 300.
  • plunger 310 is caused to move towards end cap 300. Plunger 310 moving in this way increases the volume of passage 40 for the expanding (freezing) fluid, thereby reducing the susceptibility of manifold assembly 10 to damage from the freezing fluid.
  • the amount of additional space in passage 40 between plunger 310 and end cap 300 may vary and in one embodiment may be sized so as to compensate for a full amount of fluid in passages 40 and 60 freezing within manifold assembly 10.
  • the additional space in passage 40 between plunger 310 and end cap 300 is between 10% and 20% of the total volume of passage 40 and passage 60, such as 18%.
  • manifold assembly 10 includes a volume expansion assembly 31, including a flexible bladder 600 having therein a resiliently compressible material, such as a gas.
  • Bladder 600 is disposed within passage 40 between end cap 300 and radially inwardly extending shoulder 40 A.
  • a portion of bladder 600 may be also secured within passage 40 and particularly to end cap 300, such as with an adhesive.
  • Fig. 6 shows bladder 600 in its uncompressed state
  • Fig. 7 illustrates bladder 600 in its near fully compressed state when biased by frozen washing fluid (not shown).
  • the amount of additional space in passage 40 occupied by bladder 600 in its uncompressed state may be sized in one embodiment so as to compensate for a full amount of fluid in passages 40 and 60 freezing.
  • this additional space is between 15% and 20% of the total volume of passage 40 and passage 60, such as 18%.
  • FIGs. 8 and 9 illustrate first body portions 12 according to additional example embodiments.
  • Fig. 8 illustrates first body portion 12’ for a 10-injector manifold assembly 10.
  • First body portion 12’ includes primary passage 40 which extends between longitudinal ends of first body portion 12’, and a plurality of secondary passages 60 which are in fluid
  • passage 40 gradually narrows (and/or its diameter reduces) or stays largely constant as the passage extends from a first passage end portion corresponding to inlet 50 (i.e., the right side of the drawing) for a predetermined distance. At the predetermined distance from inlet 50, passage 40 then gradually widens until passage 40 reaches a second passage end portion corresponding volume expansion assembly 30.
  • a ratio of the diameter of passage 40 at the second passage end portion to the diameter of passage 40 at the first passage end portion (at or near inlet 50) is between 1.02 and 1.30, such as 1.23.
  • Fig. 9 illustrates first body portion 12” for a five-injector manifold assembly 10.
  • First body portion 12 includes primary passage 40 which extends between longitudinal ends of first body portion 12”, and a plurality of secondary passages 60 which are in fluid
  • passage 40 gradually narrows or stays largely constant as the passage extends from a first passage end portion corresponding to inlet 50 (i.e., the right side of the drawing) for a predetermined distance. At the predetermined distance from inlet 50, passage 40 then gradually widens until passage 40 reaches a second passage end portion corresponding to volume expansion assembly 30.
  • a ratio of the diameter of passage 40 at the second passage end portion to the diameter of passage 40 at the first passage end portion (at or near inlet 50) is between 1.10 and 1.30, such as 1.23.
  • Figs. 10-12 illustrate a manifold assembly according to another example embodiment. Specifically, Figs. 10-12 illustrate manifold assembly 10’.
  • Manifold assembly 10’ as illustrated is a two-injector manifold assembly, and includes first body portion 12 and second body portion 12 operably connected thereto.
  • First body portion 12 forms the upper part of the manifold and second body portion 14 forms the lower part thereof.
  • First body portion 12 and second body portion 14 may each include a plurality of through-bores 70, with a through-bore 70 of first body portion 12 being aligned with a corresponding through-bore 70 of second body portion 14.
  • the first and second body portions may be secured together using a bolt extending through each through-bore 70 and held in place with a nut (not shown).
  • Fig. 12 illustrates the overlapping nature of first body portion 12 and second body portion 14.
  • first body portion 12 and second body port 14 define an inner space for holding at least partly therein two injectors 20.
  • first body portion 12 of manifold assembly 10’ includes a primary passage 40 and a plurality of (i.e., two) secondary passages 60 in fluid communication with passage 40, for providing washing fluid to the fluid inputs of injectors 20.
  • Primary passage 40 and secondary passages 60 are disposed between fluid inlet 50 and the fluid input of injectors 20.
  • second body portion 14 of manifold assembly 10 includes a single fluid outlet 52 which is in fluid communication with the fluid output of each injector 20.
  • second body portion 14 includes an inner passage 80 leading from the fluid outlet of each injector 20 to fluid outlet 52.
  • Each injector includes a seal member 90, such as an O-ring, disposed at the downstream end of each injector which engages with the inner surface of second body portion 14 so as to prevent fluid from flowing from fluid outlet 52, through inner passage 80 and into the space surrounding injector 20 whereupon the fluid may damage or adversely affect the operation of the actuator unit of injector 20.
  • a metal retainer 92 is welded to the downstream tip of injector 20. The outer surface of retainer 92 includes a recessed space in which seal member 90 is disposed.
  • Injector 20 further includes a seal member 95, such as an O-ring, disposed at or near the fluid input of the injector, for providing a seal and prevent fluid from passing from secondary passage 60 into the space surrounding injector 20.
  • a seal member 95 such as an O-ring
  • Fluid inlet 50 of a plurality of manifold assemblies 10’ may be connected to a single high-pressure fluid pump and fluid reservoir. In this way, plural manifold assemblies 10’ are connected within the same camera/sensor washing system, with each manifold assembly 10’ being designated for providing washing fluid to a distinct vehicle camera or sensor.
  • Manifold assembly 10’ may serve as a stand-alone valve of a camera wash system or part of a larger multi valve assembly.
  • manifold assembly 10 may include more or less than nine injectors 20, and manifold assembly 10’ may include more than two injectors 20.
  • manifold assembly 10’ may include six injectors 20 and three fluid outlets 52, with each fluid outlet being in fluid communication with two injectors 20.
  • manifold assembly 10’ may include six injectors 20 and two fluid outlets, with each fluid outlet being in fluid communication with three injectors 20.
  • Manifold assembly 10’ may also include a volume expansion assembly 30 or 31 as described hereinabove, for providing a more robust manifold assembly that is less susceptible to damage from washing fluid freezing.

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Abstract

A manifold assembly is disclosed for washing cameras or sensors of an autonomous vehicle, including a fluid inlet, a fluid passage in fluid communication with the fluid inlet, and at least one fluid outlet. The assembly includes a plurality of fluid injectors, each fluid injector disposed at least partly within the manifold assembly between the fluid passage and a fluid outlet. The fluid passage and the fluid injectors form a plurality of fluid paths in the manifold assembly. The fluid passage widens from the fluid inlet to an end portion of the manifold assembly opposite the fluid inlet. The at least one fluid outlet may be in fluid communication with a fluid output of at least at least one of the fluid injectors, or at least two of the fluid injectors. A volume expander increases fluid passage volume responsive to expansion forces from fluid in the manifold freezing.

Description

VEHICLE CAMERA AND SENSOR WASHER MANIFOLD WITH FREEZE ROBUSTNESS
Field of Invention
[0001] The present invention relates to a washing system, and particularly to a manifold assembly for use in washing cameras and other sensors having lenses mounted to the exterior of a motor vehicle.
Background
[0002] As autonomous vehicle development continues to progress with various sensors and cameras around the exterior of the vehicle, a need for keeping the lenses of these sensors and cameras clean and functioning properly has arisen. A majority of the autonomous vehicles developed are used in a capture fleet such as a taxi or delivery service. A capture fleet has the benefit of being properly maintained by trained technicians, so the risk of misuse is relatively low. However, as the technology matures, more of the autonomous vehicle technology will find its way into consumer vehicles where the risk of misuse is much higher. One potential misuse case is in the incorrect fluid (such as water or summer blend washer fluid) used in the camera/sensor wash system of an autonomous vehicle in cold climates. This can lead to damage to the wash system due to the expansion of the washing fluid during freezing conditions, especially in wash systems constructed from plastic and/or having relatively wide tolerances. Summary
[0003] Example embodiments overcome shortcomings associated with the use of cameras and sensors mounted along vehicle exteriors and thereby satisfy a need for a cleaning system for externally mounted cameras and sensors. According to an example embodiment, there is disclosed a manifold assembly for washing cameras or sensors of an autonomous vehicle, including a fluid inlet, a fluid passage in fluid communication with the fluid inlet, and one or more fluid outlets. The manifold assembly includes a plurality of fluid injectors, each of which is disposed at least partly within the manifold assembly between the fluid passage and a fluid outlet. The fluid passage and the fluid injectors form a plurality of fluid paths in the manifold assembly. In one aspect, the fluid passage widens from the fluid inlet to an end portion of the manifold assembly opposite the fluid inlet. A diameter of the fluid passage may gradually increase from the fluid inlet. In addition or in the alternative, the diameter of the fluid passage gradually decreases from the fluid inlet for a predetermined distance, and gradually increases from the predetermined distance to the end portion of the manifold assembly opposite the fluid inlet.
[0004] In another aspect, the manifold assembly includes a volume expansion assembly in fluid communication with the fluid passage. An end cap connected to an end portion of the manifold assembly is disposed opposite the fluid inlet. The volume expansion assembly increases a volume of the fluid passage responsive to expansion forces from fluid in the inner bore freezing. In one aspect, the volume expansion assembly includes a plunger member moveably disposed in the in the fluid passage, and a spring member disposed within the inner bore between the end cap and the plunger member. The manifold assembly may include an inner wall which defines the fluid passage, the inner wall including a shoulder which extends radially inwardly. The plunger member is disposed between the end cap and the shoulder, the shoulder serving as a stop for the plunger member. The spring member is configured to provide a spring force to the plunger member that is greater than fluid pressure of fluid in the fluid passage during normal operation of the manifold assembly, and less than an expansion force of the fluid when the fluid freezes.
[0005] In another aspect, the volume expansion assembly includes a collapsible bladder having a resiliently compressible gas disposed therein. The collapsible bladder is disposed at the end portion of the fluid passage opposite the fluid inlet. The collapsible bladder may be constructed from a rubber composition. The collapsible bladder may be fully contained within the fluid passage.
[0006] The manifold assembly may include a first body portion in which the fluid passage and at least part of the fluid inlet are defined, with an upstream portion of each injector being disposed in the first body portion. A downstream portion of each injector is disposed in a second body portion. Each of the first body portion and the second body portion includes a through-bore, each through-bore of the first body portion being located so as to align with a corresponding through-bore of the second body portion. The first and second body portions are aligned with each other and secured together by fastening each through-bore of the first body portion with the corresponding through-bore of the second body portion.
[0007] In one aspect, the one or more fluid outlets includes a plurality of fluid outlets, with each fluid outlet being associated with at least one fluid injector. In another aspect, the one or more fluid outlets includes a single fluid outlet, and the plurality of fluid paths are in fluid communication with the single fluid outlet.
[0008] In another example embodiment, a manifold assembly for washing camera and sensors of an autonomous vehicle includes a fluid inlet and a fluid passage in fluid
communication with the fluid inlet. The manifold assembly further includes a plurality of fluid injectors, each fluid injector disposed at least partly within the manifold assembly in fluid communication with the fluid passage. At least one fluid outlet is in fluid communication with a fluid output of at least two of the fluid injectors. The at least one fluid outlet may be a single fluid outlet.
[0009] In one aspect, each fluid injector includes a control input interface which receives one or more control signals for controlling the fluid injector, wherein each fluid injector is configured to be separately controllable.
[00010] In another aspect, the manifold assembly includes a first body portion in which the fluid passage and at least part of the fluid inlet are defined, an upstream portion of each injector being disposed in the first body portion. The manifold assembly also includes s second body portion in which a downstream portion of each injector is disposed. Each of the first body portion and the second body portion includes a through-bore, each through-bore of the first body portion being located so as to align with a corresponding through-bore of the second body portion. The first and second body portions are aligned with each other and secured together by fastening each through-bore of the first body portion with the corresponding through-bore of the second body portion.
[00011] In another aspect, the fluid passage gradually widens in a direction away from the fluid inlet.
[00012] In another aspect, a first retaining member is disposed within the second body portion downstream, relative to a flow of fluid through the manifold assembly, of a fluid output of a first injector of the plurality of injectors. The first retaining member has a radially outward facing recess. A seal member is disposed in the recess and contacts an inner surface of the second body portion. The seal member provides a seal between the second body member, the first retaining member and the first injector.
Brief Description of the Drawings [00013] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[00014] Fig. 1 is a cross sectional side view of manifold assembly of a vehicle
cam era/ sensor washing system according to an example embodiment;
[00015] Fig. 2 is a partial cross sectional side view of the manifold assembly of Fig. 1 illustrating a fluid distribution passage;
[00016] Fig. 3 is a partial cross sectional side view of the manifold assembly of Fig. 1 illustrating a volume expansion assembly thereof according to an example embodiment;
[00017] Fig. 4 is an exterior side view of the manifold assembly of Fig. 1;
[00018] Fig. 5 is a simplified view of the partial cross sectional view of Fig. 3;
[00019] Figs. 6 and 7 are simplified cross sectional views of the volume expansion assembly of the manifold assembly according to another example embodiment;
[00020] Figs. 8 and 9 illustrate cross sectional views of a body portion of the manifold assembly according to additional example embodiments;
[00021] Fig. 10 is a cross sectional view of a manifold assembly according to another example embodiment; and
[00022] Figs. 11 and 12 illustrate side and bottom elevational views, respectively, of the manifold assembly of Fig. 10.
Detailed Description
[00023] In the figures and throughout the detailed description, the same reference numbers are used to identify identical or similar elements. For the sake of clarity, the elements are not shown to scale unless otherwise specified.
[00024] In general terms, example embodiments of the present disclosure are directed to a manifold assembly of a wash systems for camera and sensors of autonomous vehicles. The manifold assembly is disposed within the vehicle and in fluid communication between a source of washing fluid and exit ports of the wash system which discharge the washing fluid towards a plurality of the vehicle’s cameras and sensors. In this way, the manifold assembly serves to provide and distribute washing fluid to the externally-facing cameras and sensors of a motor vehicle. [00025] Referring to Figs. 1-5, there is shown a manifold assembly 10 according to an example embodiment. Manifold assembly 10 is configured to be part of a camera/sensor wash system for a motor vehicle, between a source of washing fluid and the exit ports of the wash system, and particularly between a fluid pump on an upstream side and the exit ports on a downstream side of the manifold assembly 10.
[00026] Manifold assembly 10 includes an inlet 50 disposed at one longitudinal end of the assembly and configured to receive, either directly or indirectly, fluid from a source of washing fluid to be used to wash exterior-facing cameras and sensors of a motor vehicle, such as the cameras and sensors which provide autonomous control functionality. Manifold assembly 10 further includes a plurality of outlets 52 which selectively provide washing fluid received at inlet 50.
[00027] In an example embodiment, manifold assembly 10 includes a first body portion
12 and a second body portion 14. First body portion 12 forms the upper part of the manifold and second body portion 14 forms the lower part thereof. First body portion 12 and second body portion 14 may each include a plurality of through-bores 70, with a through-bore 70 of first body portion 12 being aligned with a corresponding through-bore 70 of second body portion 14. The first and second body portions may be secured together using a bolt extending through each through-bore 70 and held in place with a nut (not shown). One or more through-bores 70 may also be used for mounting manifold assembly 10 within the vehicle.
[00028] Manifold assembly 10 includes valves for selectively controlling the flow of fluid from fluid inlet 50 to fluid outlets 52. In example embodiments, the valves are fluid injectors 20, and in particular are fuel injectors. As shown in Fig. 1 and to some extent Fig. 4, first body portion 12 and second body portion 14 define a plurality of spaces when the body portions are coupled together, with each space being sized for receiving an injector 20 therein. Injectors 20 are arranged such that each injector 20 selectively passes fluid from inlet 50 to a distinct fluid outlet 52. In an example embodiment, each injector 20 is a conventional fuel injector and includes components typically found in a fuel injector, including an actuator unit having a coil, a stationary pole piece, a moveable armature which moves in response to an electromagnetic force generated from passing a current through the coil, and a spring which biases the armature; a valve assembly including a valve seat and a valve needle which is coupled to the armature for at least partial movement therewith. The valve seat engages with an end of the valve needle when the valve assembly is in the closed position and is spaced from the valve seat when the valve assembly is in the open position. Because injectors 20 are conventional fuel injectors with components that are well known, a detailed description of injector 20 will not be provided herein for reasons of expediency. In the embodiment illustrated in Fig. 1, each injector 20 includes a first seal member disposed at or near a fluid input of the injector, and a second seal member disposed at or near a fluid output of the injector. Each such seal member may be a compressible O-ring. The O-rings provide a seal between the injector 20 and the first and second body portions so as to prevent fluid from flowing around the exterior of injectors 20. As shown in Fig. 4, the electrical control interface of each injector 20 extends from first body portion 12 and second body 14 of manifold assembly 10 so as to provide easy connection to a controller or like device.
[00029] In an example embodiment, injectors 20 are independently controlled by a controller of the vehicle (not shown). In this way, the camera/sensor washing system is able to independently and separately wash each camera/sensor as needed.
[00030] Best seen in Figs. 1 and 2, first body portion 12 includes an inner bore or primary passage 40 and a plurality of secondary passages 60 which are configured to provide a fluid path from inlet 50 to the fluid input of each injector 20. Passage 40 extends from inlet 50 to an opposite (longitudinal) end portion of manifold assembly 10. Each secondary passage 60 provides fluid communication from primary passage 40 to the fluid input of a distinct injector 20.
[00031] In an example embodiment and best seen in Figs. 1 and 2, primary passage 40 gradually widens from inlet 50 at one longitudinal end portion of manifold assembly 10 to the opposite longitudinal end portion thereof. In one embodiment, primary passage 40 gradually widens such that the diameter D1 of passage 40 at the longitudinal end portion of manifold assembly 10 opposite inlet 50 is between 102% and 130% greater than the diameter D2 of primary passage 40 at inlet 50, and particularly between 115% and 125%, such as 120%. A widening primary passage 40 advantageously causes or at least allows for frozen portions of fluid within passage 40 to move along passage 40 in a direction of the widening of passage 40, i.e., in a direction away from fluid inlet 50.
[00032] In an alternative embodiment, primary passage 40 widens from inlet 50 in a non- gradual progression, such as in a step-wise manner.
[00033] Manifold assembly 10 further includes a volume expansion assembly 30 disposed in a longitudinal end portion that is opposite inlet 50. Best seen in Figs. 3 and 5 and in accordance with an example embodiment, volume expansion assembly 30 includes an end cap 300 which is sealingly engaged at the longitudinal end of primary passage 40. A plunger 310 is movably disposed within primary passage 40 between a radially inwardly extending shoulder 40A of primary passage 40 and the longitudinal end of the passage. An O-ring 320 or other seal member is disposed circumferentially around plunger 310 so as to provide a seal between plunger 310 and primary passage 40. Volume expansion assembly 30 further includes a spring 330 disposed in the space between plunger 310 and end cap 300 which biases plunger 310 in a direction towards shoulder 40A and inlet 50. As shown in Figs. 3 and 5, spring 330 includes a first end which contacts end cap 300 and a second end which contacts plunger 310. Spring 330 is configured so that plunger 310 is positioned against shoulder 40A when spring 330 is in its most uncompressed state during normal operation of manifold assembly 10 in which the fluid in passage 40 is under pressure. Spring 330 is only compressed due to movement of plunger 310 towards end cap 300 from fluid expansion forces when the washing fluid in passage 40 freezes.
[00034] In use, washing fluid is provided under pressure to primary passage 40 of manifold assembly 10. When a controller (not shown) in the vehicle determines that a camera or sensor of the vehicle needs to be washed, the controller transmits a control signal to activate or open an injector 20 corresponding to camera/sensor needing to be washed. It is understood that more than one injector may be activated at a time. The control signal is received by the selected injector 20 which energizes the coil in the injector 20 so as to cause the armature to move and displace the valve needle from the valve seat of injector 20, thereby opening the injector.
Injector 20 being opened allows the pressurized washing fluid in passage 40 to pass through the injector and exit manifold assembly 10 via the outlet 52 corresponding to the activated injector. During this operation, the pressure in passage 40 and passage 60 is such that plunger 310 is urged by spring 330 against shoulder 40A of passage 40. In other words, the spring force provided by spring 330 is greater than the forces associated with the pressurized washing fluid in passage 40.
[00035] During extreme cold temperatures, either during normal operation of the vehicle or when the vehicle is not in use, the fluid in passage 40 may freeze. The diametrically expanding frozen portions move in passage 40 in a direction of the widening passage (i.e., away from fluid inlet 50), and may eventually expand to such an extent that the frozen fluid presents an expansion force on plunger 310 in a direction towards end cap 300. When the expansion force on plunger 310 from the frozen or freezing fluid exceeds the bias force on plunger 310 from spring 330, plunger 310 is caused to move towards end cap 300. Plunger 310 moving in this way increases the volume of passage 40 for the expanding (freezing) fluid, thereby reducing the susceptibility of manifold assembly 10 to damage from the freezing fluid.
[00036] It is understood that the amount of additional space in passage 40 between plunger 310 and end cap 300 may vary and in one embodiment may be sized so as to compensate for a full amount of fluid in passages 40 and 60 freezing within manifold assembly 10. In an example embodiment, the additional space in passage 40 between plunger 310 and end cap 300 is between 10% and 20% of the total volume of passage 40 and passage 60, such as 18%.
[00037] In another example embodiment illustrated in Figs. 6 and 7, manifold assembly 10 includes a volume expansion assembly 31, including a flexible bladder 600 having therein a resiliently compressible material, such as a gas. Bladder 600 is disposed within passage 40 between end cap 300 and radially inwardly extending shoulder 40 A. A portion of bladder 600 may be also secured within passage 40 and particularly to end cap 300, such as with an adhesive. Fig. 6 shows bladder 600 in its uncompressed state, and Fig. 7 illustrates bladder 600 in its near fully compressed state when biased by frozen washing fluid (not shown). The amount of additional space in passage 40 occupied by bladder 600 in its uncompressed state may be sized in one embodiment so as to compensate for a full amount of fluid in passages 40 and 60 freezing.
In an example embodiment, this additional space is between 15% and 20% of the total volume of passage 40 and passage 60, such as 18%.
[00038] Figs. 8 and 9 illustrate first body portions 12 according to additional example embodiments. Fig. 8 illustrates first body portion 12’ for a 10-injector manifold assembly 10. First body portion 12’ includes primary passage 40 which extends between longitudinal ends of first body portion 12’, and a plurality of secondary passages 60 which are in fluid
communication with passage 40 for providing fluid to injectors 20 when injectors 20 are disposed within first body portion 12’. In Fig. 8, passage 40 gradually narrows (and/or its diameter reduces) or stays largely constant as the passage extends from a first passage end portion corresponding to inlet 50 (i.e., the right side of the drawing) for a predetermined distance. At the predetermined distance from inlet 50, passage 40 then gradually widens until passage 40 reaches a second passage end portion corresponding volume expansion assembly 30. In the embodiment illustrated, a ratio of the diameter of passage 40 at the second passage end portion to the diameter of passage 40 at the first passage end portion (at or near inlet 50) is between 1.02 and 1.30, such as 1.23.
[00039] Fig. 9 illustrates first body portion 12” for a five-injector manifold assembly 10.
First body portion 12” includes primary passage 40 which extends between longitudinal ends of first body portion 12”, and a plurality of secondary passages 60 which are in fluid
communication with passage 40 for providing fluid to injectors 20 when injectors 20 are disposed within first body portion 12”. In Fig. 9, passage 40 gradually narrows or stays largely constant as the passage extends from a first passage end portion corresponding to inlet 50 (i.e., the right side of the drawing) for a predetermined distance. At the predetermined distance from inlet 50, passage 40 then gradually widens until passage 40 reaches a second passage end portion corresponding to volume expansion assembly 30. In the embodiment illustrated, a ratio of the diameter of passage 40 at the second passage end portion to the diameter of passage 40 at the first passage end portion (at or near inlet 50) is between 1.10 and 1.30, such as 1.23.
[00040] Figs. 10-12 illustrate a manifold assembly according to another example embodiment. Specifically, Figs. 10-12 illustrate manifold assembly 10’. Manifold assembly 10’ as illustrated is a two-injector manifold assembly, and includes first body portion 12 and second body portion 12 operably connected thereto. First body portion 12 forms the upper part of the manifold and second body portion 14 forms the lower part thereof. First body portion 12 and second body portion 14 may each include a plurality of through-bores 70, with a through-bore 70 of first body portion 12 being aligned with a corresponding through-bore 70 of second body portion 14. The first and second body portions may be secured together using a bolt extending through each through-bore 70 and held in place with a nut (not shown). Fig. 12 illustrates the overlapping nature of first body portion 12 and second body portion 14.
[00041] When connected together, first body portion 12 and second body port 14 define an inner space for holding at least partly therein two injectors 20. Similar to first body portion 12 of manifold assembly 10, first body portion 12 of manifold assembly 10’ includes a primary passage 40 and a plurality of (i.e., two) secondary passages 60 in fluid communication with passage 40, for providing washing fluid to the fluid inputs of injectors 20. Primary passage 40 and secondary passages 60 are disposed between fluid inlet 50 and the fluid input of injectors 20.
[00042] Unlike second body portion 14 of manifold assembly 10, second body portion 14 of manifold assembly 10’ includes a single fluid outlet 52 which is in fluid communication with the fluid output of each injector 20. Specifically, second body portion 14 includes an inner passage 80 leading from the fluid outlet of each injector 20 to fluid outlet 52. By connecting the fluid output of each injector 20 to a single fluid outlet 52, and by configuring injectors 20 for independent control, manifold assembly 10’ advantageously allows for a selectively varied fluid pressure and/or fluid amounts exiting fluid outlet 52, thereby providing enhanced washing capabilities for a vehicle camera or sensor. Activating the two injectors 20 simultaneously advantageously allows for reduced fluid pressure drop across injectors 20.
[00043] Each injector includes a seal member 90, such as an O-ring, disposed at the downstream end of each injector which engages with the inner surface of second body portion 14 so as to prevent fluid from flowing from fluid outlet 52, through inner passage 80 and into the space surrounding injector 20 whereupon the fluid may damage or adversely affect the operation of the actuator unit of injector 20. In addition, a metal retainer 92 is welded to the downstream tip of injector 20. The outer surface of retainer 92 includes a recessed space in which seal member 90 is disposed.
[00044] Injector 20 further includes a seal member 95, such as an O-ring, disposed at or near the fluid input of the injector, for providing a seal and prevent fluid from passing from secondary passage 60 into the space surrounding injector 20.
[00045] Fluid inlet 50 of a plurality of manifold assemblies 10’ may be connected to a single high-pressure fluid pump and fluid reservoir. In this way, plural manifold assemblies 10’ are connected within the same camera/sensor washing system, with each manifold assembly 10’ being designated for providing washing fluid to a distinct vehicle camera or sensor. Manifold assembly 10’ may serve as a stand-alone valve of a camera wash system or part of a larger multi valve assembly.
[00046] It is understood that manifold assembly 10 may include more or less than nine injectors 20, and manifold assembly 10’ may include more than two injectors 20. In an example embodiment, manifold assembly 10’ may include six injectors 20 and three fluid outlets 52, with each fluid outlet being in fluid communication with two injectors 20. In another example embodiment, manifold assembly 10’ may include six injectors 20 and two fluid outlets, with each fluid outlet being in fluid communication with three injectors 20. Manifold assembly 10’ may also include a volume expansion assembly 30 or 31 as described hereinabove, for providing a more robust manifold assembly that is less susceptible to damage from washing fluid freezing. [00047] The example embodiments have been described herein 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. Obviously, many modifications and variations of the invention are possible in light of the above teachings. The description above is merely exemplary in nature and, thus, variations may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims.

Claims

CLAIMS:
1. A manifold assembly for washing cameras or sensors of an autonomous vehicle, comprising: a fluid inlet, a fluid passage in fluid communication with the fluid inlet, one or more fluid outlets, a plurality of fluid injectors, each fluid injector disposed at least partly within the manifold assembly between the fluid passage and the one or more fluid outlets, the fluid passage and the fluid injectors forming a plurality of fluid paths in the manifold assembly, wherein the fluid passage widens from the fluid inlet to an end portion of the manifold assembly opposite the fluid inlet.
2. The manifold assembly of claim 1, wherein a diameter of the fluid passage gradually increases from the fluid inlet.
3. The manifold assembly of claim 1, wherein a diameter of the fluid passage gradually decreases from the fluid inlet for a predetermined distance, and gradually increases from the predetermined distance to the end portion of the manifold assembly opposite the fluid inlet.
4. The manifold assembly of claim 1, further comprising a volume expansion assembly in fluid communication with the fluid passage, comprising an end cap connected to an end portion of the manifold assembly opposite the fluid inlet, the volume expansion assembly increasing a volume of the fluid passage responsive to expansion forces from fluid in the inner bore freezing.
5. The manifold assembly of claim 4, wherein volume expansion assembly further comprises a plunger member moveably disposed in the in the fluid passage, and a spring member disposed within the inner bore between the end cap and the plunger member.
6. The manifold assembly of claim 5, further comprising an inner wall which defines the fluid passage, the inner wall including a shoulder which extends radially inwardly, wherein the plunger member is disposed between the end cap and the shoulder, the shoulder serving as a stop for the plunger member.
7. The manifold assembly of claim 5, wherein the spring member is configured to provide a spring force to the plunger member that is greater than fluid pressure of fluid in the fluid passage during normal operation of the manifold assembly, and less than an expansion force of the fluid when the fluid freezes.
8. The manifold assembly of claim 4, wherein the volume expansion assembly further comprises a collapsible bladder having a resiliently compressible gas disposed therein, the collapsible bladder being disposed at the end portion of the fluid passage opposite the fluid inlet.
9. The manifold assembly of claim 8, wherein the collapsible bladder is constructed from a rubber composition.
10. The manifold assembly of claim 8, wherein the collapsible bladder is fully contained within the fluid passage.
11. The manifold assembly of claim 1, further comprising:
a first body portion in which the fluid passage and at least part of the fluid inlet are defined, an upstream portion of each injector being disposed in the first body portion; and
a second body portion in which a downstream portion of each injector is disposed, wherein each of the first body portion and the second body portion includes a through- bore, each through-bore of the first body portion being located so as to align with a
corresponding through-bore of the second body portion, the first and second body portions being aligned with each other and secured together by fastening each through-bore of the first body portion with the corresponding through-bore of the second body portion.
12. The manifold assembly of claim 11, further comprising: a first retaining member disposed within the second body portion downstream, relative to a flow of fluid through the manifold assembly, of a fluid output of a first injector of the plurality of injectors, the first retaining member having a radially outward facing recess; and
a seal member disposed in the recess and contacting an inner surface of the second body portion, the seal member providing a seal between the second body member, the first retaining member and the first injector.
13. The manifold assembly of claim 1, wherein the one or more fluid outlets comprises a plurality of fluid outlets, each fluid outlet being associated with at least one fluid injector.
14. The manifold assembly of claim 1, wherein the one or more fluid outlets comprises a single fluid outlet, the plurality of fluid paths are in fluid communication with the single fluid outlet.
15. A manifold assembly for washing camera and sensors of an autonomous vehicle, comprising: a fluid inlet, a fluid passage in fluid communication with the fluid inlet, a plurality of fluid injectors, each fluid injector disposed at least partly within the manifold assembly in fluid communication with the fluid passage, and at least one fluid outlet, the at least one fluid outlet being in fluid communication with a fluid output of at least two of the fluid injectors.
16. The manifold assembly of claim 15, wherein the at least one fluid outlet comprises a single fluid outlet.
17. The manifold assembly of claim 15, wherein each fluid injector includes a control input interface which receives one or more control signals for controlling the fluid injector, wherein each fluid injector is configured to be separately controllable.
18. The manifold assembly of claim 15, further comprising:
a first body portion in which the fluid passage and at least part of the fluid inlet are defined, an upstream portion of each injector being disposed in the first body portion; and
a second body portion in which a downstream portion of each injector is disposed, wherein each of the first body portion and the second body portion includes a through- bore, each through-bore of the first body portion being located so as to align with a
corresponding through-bore of the second body portion, the first and second body portions being aligned with each other and secured together by fastening each through-bore of the first body portion with the corresponding through-bore of the second body portion.
19. The manifold assembly of claim 18, wherein the fluid passage gradually widens in a direction away from the fluid inlet.
20. The manifold assembly of claim 18, further comprising:
a first retaining member disposed within the second body portion downstream, relative to a flow of fluid through the manifold assembly, of a fluid output of a first injector of the plurality of injectors, the first retaining member having a radially outward facing recess; and
a seal member disposed in the recess and contacting an inner surface of the second body portion, the seal member providing a seal between the second body member, the first retaining member and the first injector.
PCT/US2020/027410 2019-04-10 2020-04-09 Vehicle camera and sensor washer manifold with freeze robustness WO2020210450A1 (en)

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