CN109383091B - 层合玻璃面板组件和检测层合玻璃面板组件上隐藏折射率特征件的方法 - Google Patents

层合玻璃面板组件和检测层合玻璃面板组件上隐藏折射率特征件的方法 Download PDF

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CN109383091B
CN109383091B CN201810828819.5A CN201810828819A CN109383091B CN 109383091 B CN109383091 B CN 109383091B CN 201810828819 A CN201810828819 A CN 201810828819A CN 109383091 B CN109383091 B CN 109383091B
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D·G·梅勒
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Abstract

一种制造具有内玻璃层和外玻璃层的层合玻璃面板组件的方法，包括：掩蔽内玻璃层的主表面的指定区域，从而限定折射率特征件，并且将第一遮光层印刷到内玻璃层的主表面上，使得第一遮光层不存在于折射率特征件上。该方法可以包括在印刷第一遮光层之后取消对折射率特征件的掩蔽，然后将第二遮光层印刷到外玻璃层的主表面上。主表面覆盖折射率特征件或与其重叠，使得人类观察者不能透过外玻璃层看到折射率特征件，但可以使用控制器和机器视觉逻辑透过外玻璃层检测到折射率特征件。本文还描述了具有折射率特征件的玻璃面板组件，以及用于制造玻璃面板组件的系统。

Description

层合玻璃面板组件和检测层合玻璃面板组件上隐藏折射率特 征件的方法
引言
车身被配置为容纳并支撑挡风玻璃、天窗、侧车窗和后车窗，以及其他玻璃面板。例如，机动车辆的挡风玻璃可以由多层层合玻璃构造而成。聚乙烯醇缩丁醛（PVB）薄层可以夹在透明玻璃层之间，内部PVB层将玻璃层粘合在一起，同时形成对外来石块或道路碎石的屏障。然后将传感器、支架、紧固件和挡风玻璃模制件形式的硬件与挡风玻璃集成在一起以形成挡风玻璃组件。在制造过程中可以使用机器视觉系统以助于精确定位此类硬件。
发明内容
本文公开了一种制造层合玻璃面板组件的方法。该面板组件具有内玻璃层和外玻璃层。根据示例性实施例，该方法包括掩蔽内玻璃层的指定区域以限定折射率特征件，然后在内玻璃层上形成第一遮光层，使得第一遮光层不形成在折射率特征件上或上方。然后取消掩蔽折射率特征件。在外玻璃层上形成第二遮光层以覆盖指定区域或与其重叠，使得折射率特征件对外部视角而言是隐藏的，即人类观察者不能透过外玻璃层看到该折射率特征件。
该方法还包括使用光和视觉系统确定隐藏折射率特征件的位置，然后使用该确定的位置将硬件部件连接到内玻璃层。硬件部件可包括支架和/或多个紧固件，例如后视镜组件支架和用于将传感器壳体安装到玻璃面板组件的挡风玻璃变体上的紧固件。
确定隐藏折射率特征件的位置可以包括使用具有至少250流明的强度或亮度的光照射隐藏折射率特征件。
在某些实施例中，隐藏折射率特征件可以包括一个或多个圆形区域或点，而不是将本公开限制为这种形状。
还公开了一种层合玻璃面板组件，其包括内玻璃层和外玻璃层。
内玻璃层具有第一主表面，在第一主表面上形成第一遮光层。第一遮光层不存在于指定区域上，指定区域由此限定折射率特征件。外玻璃层具有第二主表面和第二遮光层。第二主表面覆盖折射率特征件或与其重叠，使得折射率特征件被有效地隐藏，即，即人类观察者不能透过外玻璃层看到该折射率特征件。当用高强度光照射玻璃面板组件时，随后可通过控制器使用机器视觉逻辑检测到隐藏折射率特征件。
隐藏折射率特征件可以位于玻璃面板组件的上中心位置。玻璃面板组件可以实施为挡风玻璃组件，在这种情况下，组件还可以包括安装到内玻璃层的后视镜组件和/或传感器壳体。
另外公开了一种用于制造层合玻璃面板组件的系统。该系统可以包括：机器人，其具有可操作以收集隐藏折射率特征件的像素图像的相机；光源，其位于临近面板组件处并配置为输出至少250流明的光；和控制器。该控制器与机器人通信，具有视觉系统逻辑，并配置为在由光源照亮挡风玻璃组件之后，使用视觉系统透过外玻璃层确定隐藏折射率特征件的位置。控制器还配置为命令机器人使用该确定的位置将硬件部件连接到内玻璃层。
机器人可以包括末端执行器，该末端执行器配置为附接支架或多个紧固件作为硬件部件。
结合附图，从下述对实施本发明的最佳模式的详细描述中，上述特征和优点以及其他特征和优点是显而易见的。
附图说明
图1是示例性机动车辆的示意性透视图，该机动车辆具有带有遮光材料的层合玻璃面板组件和如本文所公开的内容而构造的隐藏折射率特征件。
图2是图1中示出的示例性面板组件的一部分的示意性平面图。
图2A是图1和图2的面板组件的一部分的示意性侧视图。
图3是用于构造图1和图2中所示的面板组件的、基于视觉系统的示例性硬件安装过程的示意图。
本公开容易受到各种修改和替代形式的影响。在如本文详细描述的附图中，代表性实施例提供非限制性说明性示例。本公开的新颖方面不限于附图中示出的特定形式。而是，本公开旨在覆盖落入由所附权利要求限定的本公开的精神和范围内的修改、等同物、组合物或替代物。
具体实施方式
参考附图，其中相同的附图标记在若干视图中指代相同或相似的部件，图1中示出了示例性车辆10。车辆10包括限定乘客舱13的车身12。作为非限制性示例挡风玻璃组件示出的层合玻璃面板组件14经由防风雨周边垫圈（未示出）固定到车身12。车辆10可以不同地实施为客车、商业用车或工业用车、移动平台、农场设备、船舶或飞机，而不脱离预期的发明范围。
后视镜组件18和传感器壳体20可以在面板组件14的中心顶部区域16处安装到乘客舱13内的面板组件14上。传感器外壳20可以是包含诸如电光或雷达相机、雨传感器、收发器和/或温度传感器等传感器套件的塑料外壳，并且该塑料外壳将这些传感器和相关线缆与来自车辆10的乘员视线屏蔽开。
参照图2A，图1的层合玻璃面板组件14可以由上述类型（即，位于透明玻璃各自相对的内层15I和外层15O之间的聚乙烯醇缩丁醛（PVB）层）的多个不同的层合玻璃层构成。当制造面板组件14时，内层15I和外层15O会经历涂覆过程。例如，示出为遮光层17A和17B的合适着色材料或遮光材料的半透明层可以施用到面板组件14的边缘，以助于面板组件14粘合到图1的车身12上。黑色珐琅是用于此目的的常见类型的材料。可以用双层印刷工艺施用遮光层17A和17B，其中材料直接印刷到面板组件14上，遮光层17A和17B可以用作紫外线辐射屏蔽，以帮助保护和隐藏面板组件14的结构并阻挡眩光。
遮光层17A和17B可以从面板组件14的上周边边缘延伸，以覆盖图1的靠近后视镜组件18和传感器壳体20的中心顶部区域16，从而帮助遮蔽这种结构以免其被看到。人类观察者位于车辆10的外部，并且沿图2A中箭头B所示视角看向面板组件14，由于遮光层17A和17B相对于该人类观察者的位置，参考图2、如上述方式而构造的折射率特征件25则在视野中被隐藏，即，不轻易为人类观察者所能看到。如下文参考图3所述描述的，虽然折射率特征件25有效地在视野中被隐藏，但是折射率特征件25具有的在硬件安装过程30期间定位和安装支架24或其他硬件的定位功能被保留。
为了将后视镜组件18和传感器壳体20精确地安装到图1的层合玻璃面板组件14上，且在将面板组件14的周边连接到车身12之前，面板组件14可以首先经历图3中示意性描绘的硬件安装过程30。示例性挡风玻璃硬件如图2所示，其中面板组件14的部分在上述双层遮光印刷过程中涂有黑色环氧树脂或其它合适的遮光材料。图2A中所示的遮光材料17A和17B一起形成半透明遮光部分14B，面板组件14的透明/通明部分14C定位在遮光部分14B附近。如图所示，一旦面板组件14组装完全，塑料模制件或挡风玻璃装饰件26可以可选地围绕住遮光部分14B。
示例性挡风玻璃硬件在硬件安装区域21中示出为可选的一组紧固件22，例如，桩或安装螺柱，其最终与图1的传感器壳体20上的配合紧固件（未示出）接合。用于将图1的后视镜组件18固定到面板组件14的玻璃上的支架24可以固定或结合到硬件安装区域21内的面板组件14上。存在于硬件安装区域21中的每片挡风玻璃硬件可以是机器安装的，例如，使用诸如图3的机器人32的多轴工业机器人来安装，从而确保精确定位和可重复定位紧固件22、支架24或其他硬件。
可以通过如下文参考图3所述的视觉系统来辅助图2中所示硬件的机器安装。作为这一过程的一部分，可以对硬件安装区域21的图像加以处理以确定每个硬件相对于校准的参考位置的二维或三维坐标，该参考位置是折射率特征件25的坐标。该折射率特征件例如是图2的示例性说明中的一对折射率特征件25A和25B，其在不同的实施例中可以是圆形、线形、X形、正方形或其他合适的形状。
折射率特征件25A和25B可以在双层遮光印刷过程期间形成在遮光区域14B中，并且随后通过装饰件26而被遮挡住在来自图1的乘客舱13的视野之中。如本文所述，折射率特征件25A和25B被实施为面板组件14的内层15I（参见图2A）上的透明未涂覆区域或点，或线性散列标记/刻度标记，或未涂覆遮光材料17A的其他合适区域。仍然将遮光材料17A施用到面板组件14的相邻外层，使得当通过面板组件14观察时，折射率特征件25在图1的车辆10外部是不可见的。通过插入图2的装饰件26，在乘客舱内也看不见折射率特征件25。
例如，上述折射率特征件25可以在面板组件14的制造期间形成，特别是在双层遮光过程期间形成。构造可以包括掩蔽面板组件14的内玻璃层15I的主表面19的一个或多个小圆形区域或线性散列标记/刻度标记或其他次表面区域。这一过程可以包括应用可移除的屏幕、模板、护罩，或在施用时阻挡遮光材料17A与内层15I的接触的其他掩蔽件。那么当在内玻璃层15I的主表面19上形成图2A的遮光层17A时，遮光层17A不被印刷到掩蔽区域上。
此后，该方法可以包括在将遮光层17B印刷到外玻璃层15O的主表面190上之前，取消对先前掩蔽的次表面区域（即，对应于折射率特征件25的区域）的掩蔽。外玻璃层15O的主表面190覆盖次表面区域/折射率特征件25或与其重叠，即，主表面190设置在位于车辆10外部的观察者与折射率特征件25之间。结果，当观察者观察对应于折射率特征件25的区域时，这样的观察者看到遮光层17B的材料而看不到折射率特征件25。然而，因为遮光材料17A没有覆盖内层15I上的折射率特征件25，所以图3的硬件安装过程30仍然可用于放置图2中所示的示例性挡风玻璃硬件。
参照图3，上文简要提到的硬件安装过程30可以使用机器人32进行，该机器人32例如是响应于来自控制器（C）50的运动控制信号（箭头CCM）的六轴工业机器人或其他多轴工业机器人。虽然示出为安装在地板上的机器人，但是在其他实施例中，机器人32可以悬挂在头顶上，比如从轨道或传动定位系统悬挂下来，使得执行必要的硬件安装步骤（例如钻孔，胶合等）的机器人32的末端执行器36响应于运动控制信号（箭头CCM）自由平移并旋转到命令位置。控制器50可以实施为具有必需存储器（M）的一个或多个计算机设备和分别存储和执行用于控制机器人32的算法/软件的处理器（P），以及其他相关硬件，例如时钟或定时器、输入/输出电路等。存储器（M）包括足够量的只读存储器（ROM），例如磁存储器或光存储器。
作为硬件安装过程30的一部分，当一系列组件14沿箭头A的方向沿传送带33移动时，机器人32可在层合玻璃面板组件14上操作，即，作为移动生产线过程的一部分。或者，机器人32可以相对于面板组件14移动，同时面板组件14保持静止。机器人32可以配备有与控制器50通信的视觉系统相机35，又使用相应的视觉系统逻辑100对控制器50进行编程。
作为硬件安装过程30的一部分，视觉系统相机35对层合玻璃面板组件14进行成像或扫描，并使用视觉系统逻辑100检测对比区域。然后将对比区域的相应位置作为位置数据（箭头PXYZ）报告给控制器50。以这种方式，控制器50被配置为使用机器视觉功能而作为整体硬件安装过程30的一部分。举例来说，视觉系统相机35可以捕获光并将光转换成电信号，然后将电信号数字化为像素阵列并通过控制器50处理以确定折射率特征件25的相应三维坐标。
特别地，在安装图2所示的示例性挡风玻璃硬件之前，控制器50操作视觉系统相机35并使用视觉系统逻辑100来检测面板组件14上的折射率特征件25。如上所述，透过图2A的遮光层17B看不到折射率特征件25。因此，硬件安装过程30包括用来自高强度光源40的光（箭头L）照射面板组件14的下侧（即，面向乘客舱13的表面）。例如，可以激励一组发光二极管（LED）或白炽灯或卤素灯泡，使得高强度光（箭头L）沿与图2A中箭头B所示方向径向相反的方向照射折射率特征件25。如本文所使用的，术语“高强度”的含义可以随着光（箭头L）通过的遮光层17B的厚度和材料类型以及视觉系统相机35的灵敏度变化而变化。作为非限制性示例，至少250流明的光（箭头L）在被集中并且被引导到折射率特征件25中时，这样的光强度会是合乎要求的。然而，如果光（箭头L）被漫射，或者如果光源40被放置得离面板组件14更远，则可以使用1000流明或更高的高强度光。其他方法可包括使用高强度频闪灯或聚光灯。
在形成当前被隐藏的折射率特征件25之后，本文描述的方法可以包括使用由光源40发射的光（箭头L）和视觉系统（即，视觉系统相机35和相关的视觉系统逻辑100）确定与折射率特征件25相对应的次表面区域的位置。一旦折射率特征件25的位置被传送到控制器50，控制器50可操作以命令机器人32使用所确定的位置将硬件部件连接到面板组件14。也就是说，所确定的折射率特征件25的位置变为参考点，控制器50从该参考点计算硬件的所需对应位置，并且继而控制图3的末端执行器36以附接硬件。
除了上述益处之外，如图2A所示的折射率特征件25的放置方式改善了与其他特征件空隙对准的精度，这些空隙可能包括相机空隙和/或雨感空隙。遮光层17A和17B对于它们各自的玻璃层具有对准公差，并且玻璃层本身具有彼此间的对准公差。通过将折射率特征件25移动到与特征件空隙相同的玻璃层上，大部分公差叠加得以消除。
虽然已经详细描述了用于执行本公开的最佳模式，但是熟悉本公开所涉及领域的技术人员将认识到存在用于在所附权利要求的范围内实践本公开的各种替代设计和实施例。

Claims (10)

1.一种制造具有内玻璃层和外玻璃层的层合玻璃面板组件的方法，所述方法包括：
掩蔽所述内玻璃层的主表面的指定区域，从而限定折射率特征件；
将第一遮光层印刷到所述内玻璃层的所述主表面上，使得所述第一遮光层不印刷到限定所述折射率特征件的所述指定区域上；
在印刷所述第一遮光层后取消掩蔽所述折射率特征件的所述指定区域；
将第二遮光层印刷到所述外玻璃层的主表面上，使得所述外玻璃层的所述主表面覆盖所述折射率特征件或与其重叠，并使得人类观察者不能透过所述外玻璃层看到所述折射率特征件；
用高强度光照亮所述面板组件；并且
在照亮所述面板组件之后，使用视觉系统相机和控制器通过所述外玻璃层确定所述折射率特征件的位置。
2.根据权利要求1所述的方法，进一步包括：
使用所述确定的位置将硬件部件连接到所述内玻璃层。
3.根据权利要求2所述的方法，其中所述面板组件是挡风玻璃组件，所述硬件部件是后视镜支架。
4.根据权利要求2所述的方法，其中所述面板组件是挡风玻璃组件，所述硬件部件是多个紧固件，其配置成安装传感器壳体。
5.根据权利要求2所述的方法，其中确定所述折射率特征件的所述位置包括用强度至少为250流明的光照射所述折射率特征件。
6.根据权利要求5所述的方法，其中确定所述折射率特征件的所述位置包括用强度至少为1000流明的光照射所述折射率特征件。
7.一种层合玻璃面板组件，包括：
内玻璃层，其具有第一主表面和印刷在所述第一主表面上的第一遮光层，其中所述第一遮光层不存在于限定折射率特征件的指定区域上；和
外玻璃层，其具有第二主表面和印刷在所述第二主表面上的第二遮光层，所述第二遮光层覆盖所述折射率特征件或与其重叠，使得人类观察者不能透过所述外玻璃层看到所述折射率特征件，并且当使用高强度光照射所述面板组件时，通过控制器使用视觉系统相机和机器视觉逻辑可透过所述外玻璃层检测到所述折射率特征件。
8.根据权利要求7所述的面板组件，其中所述面板组件是挡风玻璃组件，所述面板组件还包括后视镜组件和安装到所述内玻璃层的传感器外壳中的一者或两者。
9.根据权利要求7所述的面板组件，其中所述折射率特征件包括多个折射率特征件。
10.根据权利要求9所述的面板组件，其中所述面板组件是挡风玻璃组件，并且其中所述多个折射率特征件位于所述面板组件的上中心位置。
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