The Role of Additive Manufacturing in the Integration of Autonomous Vehicle Sensors
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Date
2021-12
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The Ohio State University
Abstract
In autonomous vehicles, advanced driver-assistance systems are essential for autonomous
functions such as adaptive cruise control, lane departure and centering, and driver alerts such as
collision warning. ADAS sensors, such as radars, cameras, and lidars, have a field of view which
is the area that the sensor is able to detect an object. By placing the sensors in certain locations,
one is able to overlap the field of views to form a model of the environment surrounding the
vehicle that is used for situational assessment to determine whether to implement action. In
autonomous vehicle design, it is critical that the ADAS sensors are placed and oriented so that
their combined field of views are able to capture what is necessary for autonomous vehicle
functions and vehicle safety. ADAS sensors require high positional accuracy to function properly
and have a small tolerance for changes in orientation. The goal of this research is to position and
use additive manufacturing techniques to create mounting solutions for integrating ADAS
sensors onto a 2019 Chevy Blazer for the EcoCAR Mobility Challenge competition focusing on
precision and optimal configuration.
The ADAS sensors positions on the vehicle were decided based on CAD representations
of the overlapping fields of view simulated in the modeling software NX and data from physical
testing of the sensors at predetermined locations with prototypes created using fused filament
fabrication techniques. For the final design, Aptiv MRR sensors were mounted onto the rear side
doors at 2 and 178 degrees roll and the front corners at 130 degrees yaw. Delphi ESR 2.5 sensors were mounted onto the front and rear bumpers of the car, and a Mobileye 6 Series camera was
mounted onto the top of the windshield off-center on the passenger side. The Aptiv and Delphi
radar sensors were mounted with 3D-printed mounts made from Polycarbonate filament, which
has a high heat deflection rate to prevent warping. The Mobileye camera was mounted with a
3D-printed mount made from Acrylonitrile butadiene styrene (ABS) filament and small
aluminum disks. This is the optimal ADAS sensor configuration because it creates a combined
field of views that captures all the necessary information for the safe use of the team's desired
autonomous functions.