U.S. patent application number 15/827038 was filed with the patent office on 2019-05-30 for washer fluid tank with magnetically responsive sensors.
This patent application is currently assigned to Ford Global Technologies, LLC. The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Segundo Baldovino, Paul Kenneth Dellock, Venkatesh Krishnan, Stuart C. Salter.
Application Number | 20190161035 15/827038 |
Document ID | / |
Family ID | 66548416 |
Filed Date | 2019-05-30 |
United States Patent
Application |
20190161035 |
Kind Code |
A1 |
Salter; Stuart C. ; et
al. |
May 30, 2019 |
WASHER FLUID TANK WITH MAGNETICALLY RESPONSIVE SENSORS
Abstract
A washer fluid tank assembly for vehicle mounting includes a
tank, a track, a float and two magnetically-responsive sensors. The
tank has a fill opening. The track is formed in a first wall of and
inside the tank. The float is slidably disposed on the track and
has a magnet thereon proximate to a second wall of the tank. The
magnetically-responsive sensors are fixed to the second wall of the
tank in alignment with the track. The sensors are each associated
with a predetermined fluid volume.
Inventors: |
Salter; Stuart C.; (White
Lake, MI) ; Baldovino; Segundo; (Novi, MI) ;
Dellock; Paul Kenneth; (Northville, MI) ; Krishnan;
Venkatesh; (Canton, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
Ford Global Technologies,
LLC
Dearborn
MI
|
Family ID: |
66548416 |
Appl. No.: |
15/827038 |
Filed: |
November 30, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60S 1/50 20130101; G01D
5/145 20130101; B60R 16/0232 20130101; B60S 5/00 20130101; G01F
23/74 20130101; G01F 23/0069 20130101; G01F 23/76 20130101 |
International
Class: |
B60R 16/023 20060101
B60R016/023; G01D 5/14 20060101 G01D005/14; G01F 23/74 20060101
G01F023/74; G01F 23/00 20060101 G01F023/00 |
Claims
1. A washer fluid tank assembly for vehicle mounting comprising: a
tank having a fill opening; a track formed in a first wall of and
inside the tank, wherein the track is fixed relative to the tank; a
float slidably disposed on the track having a magnet thereon
proximate to a second wall of the tank; and two
magnetically-responsive sensors fixed to the second wall of the
tank in alignment with the track and each associated with a
predetermined fluid volume.
2. The washer fluid tank assembly of claim 1, wherein the track is
defined by a rail on which the float is non-rotatably disposed.
3. The washer fluid tank assembly of claim 2, wherein the float
includes a track groove that receives the rail.
4. The washer fluid tank assembly of claim 3, wherein the track
groove has an open side that snaps over the rail for retention
thereon.
5. The washer fluid tank assembly of claim 1, the tank further
comprising a first part and a second part with the track being
formed in the first part and the parts being bonded together.
6. The washer fluid tank assembly of claim 5, wherein the first
part and the second part are injection-molded plastic formings.
7. The washer fluid tank assembly of claim 5, wherein the float is
installed before the first part and the second part are bonded
together.
8. The washer fluid tank assembly of claim 1, wherein the sensors
are bonded to an outside of the tank.
9. The washer fluid tank assembly of claim 1, wherein a first of
the sensors is associated with a first fluid volume of less than
half of a capacity of the tank.
10. The washer fluid tank assembly of claim 9, wherein a second of
the sensors is associated with a second fluid volume of less than
the first fluid volume.
11. A vehicle visibility washer system comprising: a first tank
having a fill opening; a first track formed in a first wall of and
inside the tank; a first float slidably disposed on the track
having a first magnet thereon proximate to a second wall of the
tank; two magnetically-responsive sensors fixed to the second wall
of the tank in alignment with the track and each associated with a
predetermined fluid volume; a pumping unit connected to the tank
for fluid communication therefrom; a plurality of visual sensor
cleaners connected to the pumping unit for fluid communication
therefrom; a windshield washer nozzle connected to the pumping unit
for fluid communication therefrom; and a controller electronically
connected to the magnetically-responsive sensors, the pumping unit,
the nozzle and the cleaners.
12. The washer system of claim 11, the pumping unit including a
first pump and a second pump, the first pump being connected to the
windshield washer nozzle for fluid communication thereto and the
second pump being connected to the visual sensor cleaners for fluid
communication thereto, and each pump being connected with the tank
for fluid communication therefrom and the controller being
electronically connected to the pumps.
13. The washer system of claim 12, further comprising: a second
tank; a second track formed in a first wall of and inside the
second tank; a second float slidably disposed on the second track
having a second magnet thereon proximate to a second wall of the
second tank; a third magnetically-responsive sensor disposed on a
second wall of the second tank; and a third pump connected to the
second tank for fluid communication therefrom and to a second
plurality of visual sensor cleaners for fluid communication
thereto. a dual filler neck connected to each of the first tank and
the second tank.
14. The washer system of claim 13, further comprising a vent in the
second tank.
15. The washer system of claim 13, further comprising a first pipe
and a second pipe connecting the dual filler neck to the tanks with
the first pipe disposed between the dual filler neck and the first
tank and the second pipe disposed between the dual filler neck and
the second tank.
16. The washer system of claim 15, further comprising a check valve
disposed between the dual filler neck and the second tank.
17. The washer system of claim 13, wherein the first track includes
a first rail on which the first float is slidably disposed, and the
second track includes a second rail on which the second float is
slidably disposed.
18. The washer system of claim 17, wherein: the first float
includes a first track groove that receives the first rail, and the
first track groove has an open side that snaps over the first rail
for retention thereon; and the second float includes a second track
groove that receives the second rail, and the second track groove
has an open side that snaps over the second rail for retention
thereon.
19. A method of cleaning visual sensors, the method comprising the
steps of: providing a tank; providing a track formed in a first
wall of and inside the tank; providing a float slidably disposed on
the track having a magnet thereon proximate to a second wall of the
tank; providing a first magnetically-responsive sensor and a second
magnetically-responsive sensor with each fixed to the second wall
of the tank and in alignment with the track and each of the
magnetically-responsive sensors being associated with a
predetermined fluid volume. providing a pumping unit connected to
the tank for fluid communication therefrom; providing a plurality
of visual sensor cleaners connected to the pumping unit for fluid
communication therefrom; providing a windshield washer nozzle
connected to the pumping unit for fluid communication therefrom;
and providing a controller electronically connected to the
magnetically-responsive sensors, the pumping unit, the nozzle and
the cleaners; determining if the float has moved within a sensing
range of the first magnetically-responsive sensor; continuing to
determine whether the float has moved within the sensing range of
the first magnetically-responsive sensor when the float has not
moved within the sensing range of the first magnetically-responsive
sensor; and restricting fluid to the windshield washer nozzle when
the float has moved within the sensing range of the first
magnetically-responsive sensor.
20. The method of claim 19, further comprising the steps of:
determining if the float has moved within a sensing range of the
second magnetically-responsive sensor; continuing to determine
whether the float has moved within the sensing range of the second
magnetically-responsive sensor when the float has not moved within
the sensing range of the second magnetically-responsive sensor; and
when the float has moved within the sensing range of the second
magnetically-responsive sensor, determining a volume of fluid
remaining in the tank, determining a volume of fluid required to
complete a trip, and comparing the volume of fluid remaining with
the volume of fluid required to determine if there is sufficient
fluid to complete the trip.
Description
BACKGROUND
[0001] Autonomous vehicles and vehicles with advanced driver
assistance systems ("ADAS") may employ a plurality of visual
sensors providing a controller or controllers with
situational-awareness data including image data indicative of
traffic, proximity to other vehicles, traffic control signals,
traffic lane locations, etc. Example visual sensors include cameras
and LIDAR sensors. Such visual sensors need to be kept clean to
allow the vehicle to continue operating. Fluid washers may be used
to clean the sensors. However, such systems are only effective when
they have an available supply of washer fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is a schematic representation of an example washer
system.
[0003] FIG. 2 is a perspective view of an example tank
assembly.
[0004] FIG. 3 is a section view of the tank assembly of FIG. 2
taken through plane 3 in the direction of arrows 3.
[0005] FIG. 4 is a section view of the tank assembly of FIG. 2
taken through plane 4 in the direction of arrows 4.
[0006] FIG. 5 is a first side view of one side of an alternative
embodiment of the tank assembly.
[0007] FIG. 6 is a perspective side view of the side of the tank of
FIG. 5.
[0008] FIG. 7 is an example flowchart of an example process
executed by the washer system.
DETAILED DESCRIPTION
[0009] Relative orientations and directions (by way of example,
upper, lower, bottom, forward, rearward, front, rear, back,
outboard, inboard, inward, outward, lateral, left, right) are set
forth in this description not as limitations, but for the
convenience of the reader in picturing at least one embodiment of
the structures described. Such example orientations are from the
perspective of an occupant seated in a seat, facing a dashboard. In
the Figures, like numerals indicate like parts throughout the
several views.
[0010] A washer fluid tank assembly for vehicle mounting includes a
tank, a track, a float and two magnetically-responsive sensors. The
tank has a fill opening. The track is formed in a first wall of and
inside the tank. The float is slidably disposed on the track and
has a magnet thereon proximate to a second wall of the tank. The
magnetically-responsive sensors are fixed to the second wall of the
tank in alignment with the track. The sensors are each associated
with a predetermined fluid volume.
[0011] The track may be defined by a rail on which the float is
non-rotatably disposed.
[0012] The float may include a track groove that receives the
rail.
[0013] The track groove may have an open side that snaps over the
rail for retention thereon.
[0014] The tank may further include a first part and a second part
with the track being formed in the first part and the parts being
bonded together.
[0015] The first part and the second part of the tank may be
injection-molded plastic formings.
[0016] The float may be installed before the first part and the
second part are bonded together.
[0017] The sensors may be bonded to an outside of the tank.
[0018] A first of the sensors may be associated with a first fluid
volume of less than half of a capacity of the tank.
[0019] A second of the sensors may be associated with a second
fluid volume of less than the first fluid volume.
[0020] A vehicle visibility washer system includes a first tank, a
first track, a first float, two magnetically responsive sensors, a
first pumping unit, a plurality of visual sensor cleaners, a
windshield washer nozzle, and a controller. The first tank has a
fill opening. The first track is formed in a first wall of and
inside the tank. The first float is slidably disposed on the track
and has a first magnet thereon proximate to a second wall of the
tank. The two magnetically-responsive sensors are fixed to the
second wall of the tank in alignment with the track. Each sensor is
associated with a predetermined fluid volume. The pumping unit is
connected to the tank for fluid communication therefrom. The
plurality of visual sensor cleaners is connected to the pumping
unit for fluid communication therefrom. The windshield washer
nozzle is connected to the pumping unit for fluid communication
therefrom. The controller is electronically connected to the
magnetically-responsive sensors, the pumping unit, the nozzle and
the cleaners.
[0021] The pumping unit may include a first pump and a second pump.
The first pump may be connected to the windshield washer nozzle for
fluid communication thereto. The second pump may be connected to
the visual sensor cleaners for fluid communication thereto. Each
pump may be connected with the tank for fluid communication
therefrom. The controller may be electronically connected to the
pumps.
[0022] The washer system may further include a second tank, a
second track, a second float, a third magnetically-responsive
sensor, a third pump and a dual filler neck. The second track may
be formed in a first wall of and inside the second tank. The second
float may be slidably disposed on the second track and may have a
second magnet thereon proximate to a first wall of the second tank.
The third magnetically-responsive sensor may be disposed on a
second wall of the second tank. The third pump may be connected to
the second tank for fluid communication therefrom, and to a second
plurality of visual sensor cleaners for fluid communication
thereto. The dual filler neck may connect to each of the first tank
and the second tank.
[0023] The washer system may further include a vent in the second
tank.
[0024] The washer system may further include a first pipe and a
second pipe connecting the dual filler neck to the tanks. The first
pipe may be disposed between the dual filler neck and the first
tank. The second pipe may be disposed between the dual filler neck
and the second tank.
[0025] The washer system may further include a check valve disposed
between the dual filler neck and the second tank.
[0026] The first track may include a first rail on which the first
float is slidably disposed. The second track may include a second
rail on which the second float is slidably disposed.
[0027] The first float may include a first track groove that
receives the first rail. The first track groove may have an open
side that snaps over the first rail for retention thereon. The
second float may include a second track groove that receives the
second rail. The second track groove may have an open side that
snaps over the second rail for retention thereon.
[0028] A method of cleaning visual sensors including the steps of
providing a tank, providing a track, providing a float, providing a
first magnetically-responsive sensor and a second
magnetically-responsive sensor, providing a pumping unit, providing
a plurality of visual sensor cleaners, providing a windshield
washer nozzle, and providing a controller. The track may be formed
in a first wall of and inside the tank. The float may be slidably
disposed on the track, and may have a magnet thereon proximate to a
second wall of the tank. The first magnetically-responsive sensor
and the second magnetically-responsive sensor may be fixed to the
second wall of the tank and may be in alignment with the track.
Each of the magnetically-responsive sensors may be associated with
a predetermined fluid volume. The pumping unit may be connected to
the tank for fluid communication therefrom. The plurality of visual
sensor cleaners may be connected to the pumping unit for fluid
communication therefrom. The windshield washer nozzle may be
connected to the pumping unit for fluid communication therefrom.
The controller may be electronically connected to the
magnetically-responsive sensors, the pumping unit, the nozzle and
the cleaners. It may be determined if the float has moved within a
sensing range of the first magnetically-responsive sensor. It may
be continued to determine whether the float has moved within the
sensing range of the first magnetically-responsive sensor when the
float has not moved within the sensing range of the first
magnetically-responsive sensor. Fluid to the windshield washer
nozzle may be restricted when the float has moved within the
sensing range of the first magnetically-responsive sensor.
[0029] The method of cleaning visual sensors may further include
the following steps. It may be determined if the float has moved
within a sensing range of the second magnetically-responsive
sensor. When it is determined that the float has not moved within
the sensing range of the second magnetically-responsive sensor,
determining whether the float has moved within the sensing range of
the second magnetically-responsive sensor when the float may be
continued. When it is determined that the float has moved within
the sensing range of the second magnetically-responsive sensor, a
volume of fluid remaining in the tank may be determined, a volume
of fluid required to complete a trip may be determined, and the
volume of fluid remaining may be compared with the volume of fluid
required to determine if there is sufficient fluid to complete the
trip.
[0030] An example vehicle visibility washer system 10 employing a
first tank assembly 12 for washer fluid, i.e., a first washer fluid
tank assembly, and a method of using the same are illustrated in
FIGS. 1-7. The washer system 10 is well suited for (but not limited
to) use in a vehicle 13 that may operate in a semiautonomous mode,
i.e., a partly autonomous mode of operation requiring some, i.e.,
occasional, human driver intervention, or a fully autonomous mode,
i.e., a fully autonomous mode requiring no human driver
intervention. For purposes of this disclosure, an autonomous mode
is defined as one in which each of vehicle propulsion (e.g., via a
powertrain including an electric motor and/or an internal
combustion engine), braking, and steering are controlled by an
autonomous vehicle controller, i.e., a computing device (or
devices); in a semi-autonomous mode the controller controls one or
two of vehicle propulsion, braking, and steering.
[0031] The system 10, as schematically illustrated in FIG. 1, may
include, in addition to the first tank assembly 12, a second tank
assembly 14 for washer fluid, i.e., a second washer fluid tank
assembly. A dual filler neck 16 may be provided to allow
simultaneous filling of the tank assemblies 12 and 14. The dual
filler neck 16 may be connected to the first tank assembly 12 by a
first supply pipe 18 and to the second tank assembly 14 by a second
supply pipe 20. A check valve 22 may be disposed at an end of the
second supply pipe 20 to prevent fluid from tank assembly 14 from
flowing back toward the dual filler neck 16. The second tank
assembly 14 may also include a vent 24 to exhaust air from the tank
assembly 14 as it is being filled.
[0032] The tank assemblies 12, 14 may be used to provide liquid
washer fluid to windows, e.g., a windshield 28 and a backlite 36,
and visual sensors 32, 40, e.g., cameras, LIDARs. FIG. 1
illustrates an example arrangement. The first tank assembly 12 may
include a first tank 64, a first float 74, a first washer fluid
sensor assembly 100 which may be a dual level washer fluid sensor
assembly, and a first pumping unit 42. The second tank assembly 14
may include a second tank 108, a second float 110, a second washer
fluid sensor assembly, and a second pumping unit 44. The tank
assemblies 12, 14 may be used to supply washer fluid to the
vehicle's 13 windows and visual sensors. More specifically, a
windshield washer nozzle 26, a representation of which in FIG. 1
includes a schematic triangular spray pattern, may be provided to
allow washer fluid to be dispensed on the windshield 28. A
plurality of first visual sensor cleaners 30 may be used to clean a
plurality of first visual sensors 32, e.g., cameras, LIDARs. A rear
washer nozzle 34, a representation of which in FIG. 1 includes a
schematic triangular spray pattern, may be provided to allow washer
fluid to be dispensed on the backlite 36. A plurality of second
visual sensor cleaners 38 may be used to clean a plurality of
second visual sensors 40, e.g., cameras, LIDARs. The first and
second visual sensor cleaners 30, 38 differ primarily in being
associated with the first and second tank assemblies 12, 14.
[0033] Pressurized liquid washer fluid is supplied to nozzles 26,
34 and cleaners 30, 38 by the first pumping unit 42 of the first
tank assembly 12 for fluid communication therefrom and a second
pumping unit 44 of the second tank assembly 14 for fluid
communication therefrom. The pumping units 42, 44 may each include
a plurality of pumps. In the example system 10, the first pumping
unit 42 includes two pumps, a first pump 46 and a second pump 48.
The example second pumping unit 44 is shown with a third pump 50.
Each of the pumps 46, 48, 50, comprising part of their respective
pumping units 42, 44, are connected to their respective tanks 64,
108 for fluid communication therefrom, and to their respective
sensor cleaners 30, 38 for communication of fluid thereto.
[0034] The first pump 46 may supply pressurized washer fluid to the
windshield washer nozzle 26, and to a first plurality of first
visual sensor cleaners 30 to clean certain of the sensors 32, e.g.,
a front camera and two front LIDARs. The second pump 48 may supply
pressurized washer fluid to a second plurality of first visual
sensor cleaners 30 to clean others of the sensors 32, e.g., cameras
on the right and left sides of a vehicle roof. The third pump 50,
disposed in the second tank assembly 14, may supply pressurized
washer fluid to the second visual sensor cleaners 38 and to the
rear, i.e., backlite, washer nozzle 34. The washer fluid may be
communicated from the pumps 46, 48, 50 to the nozzles 26, 34 and
cleaners 30, 38 through a plurality of fluid connecting lines 52,
e.g., flexible elastomeric tubes, rigid pipes, etc.
[0035] Components, e.g., the nozzles 26, 34, the cleaners 30, 38,
the pumps 46, 48, 50, and sensors 32, 40, may be electronically
connected to an autonomous vehicle controller 54 by a vehicle
network 56. The controller 54 and the network 56 comprise part of
the system 10. FIG. 1 shows an example network 56 including a
plurality of electronic connectors in the form of electronic
connecting lines 58, e.g., wires, disposed between the controller
54 and the nozzles 26, 34, the cleaners 30, 38, the pumps 46, 48,
50 and the sensors 32, 40. The vehicle network 56 may also include
an Ethernet network or a controller area network ("CAN") bus or the
like that comprise in part the electronic connectors. The network
56 may be configured for using other wired or wireless protocols,
e.g., Bluetooth, etc. A wired link from the components directly to
the controller 54 is thus not required to provide an electronic
connector between the controller 54 and the components 26, 34, 30,
38, 46, 48, 50.
[0036] The system 10 may be operated by the autonomous vehicle
controller 54. The controller 54, i.e., a computing device (or
devices) may be known as an electronic control unit, i.e., an ECU,
and may include a virtual driver system ("VDS"). The controller 54
includes at least one electronic processor and an associated
memory. The memory includes one or more forms of computer-readable
media, and stores instructions executable by the processor for
control of the system 10, e.g., performing various system
operations, including such operations as disclosed herein.
[0037] The memory of the controller 54 further generally stores
remote data received via various communications mechanisms. The
controller 54 may also have a connection to an onboard diagnostics
connector such as an OBD-II connector (not shown). Via the CAN bus,
OBD-II, Ethernet, and/or other wired or wireless mechanisms, the
controller 54 may transmit messages to various devices in the
vehicle 13 and/or receive messages from the various devices, e.g.,
the pumps 46, 48, the nozzles 26, 34, the sensors 32, 40 as
discussed herein. Although the controller 54 is shown as a single
controller in FIG. 1 for ease of illustration, it is to be
understood that the controller 54 may include and various
operations described herein could be carried out by one or more
computing devices, e.g., vehicle component controllers such as are
known and/or a computing device dedicated to the system 10.
[0038] The cleaners 30, 38 and the nozzles 26, 34 may include
actuation valves (not shown), either integral or non-integral,
allowing the cleaners 30, 38 and nozzles 26, 34 to spray or
otherwise distribute fluid in response to electronic signals from
the controller 54.
[0039] The system 10 may include environmental sensors, e.g., a
rain sensor 60 and a temperature sensor (not shown) electronically
connected to the controller 54 as discussed above. The system 10
may be in communication with a remote base or office 62. The remote
office 62 may provide command and coordination information, e.g.,
destination information, service depot locations, dispatch
instructions, etc. to the vehicle 13 in which the system 10 is
mounted.
[0040] As illustrated in FIGS. 2-4, the first tank assembly 12
includes the first tank 64 that may include a first tank half shell
66 and a second tank half shell 68. Each of the tank half shells
66, 68 may be an injection-molded plastic forming, with each of the
half shells 66, 68 being injection molded of plastic, e.g.,
thermoplastic polyurethane (i.e., "TPU"). An injection mold may be
formed by a pair of facing dies. The mold may receive liquid
plastic under pressure. Once formed, the half shells 66, 68 may be
bonded together, e.g., heat welded, sonic welded, adhesively
bonded, to form the first tank 64. Alternative materials and
forming techniques may include vacuum forming and ABS
(Acrylonitrile-Butadine-Styrene) plastic sheets. The tank 64 may be
formed of more than two parts 66, 68 when, for example, the shape
of the tank 64 is too complex to be formed in just two parts.
[0041] A fill opening 70 is provided in the tank 64 to allow the
washer fluid to enter the tank 64. The fill opening 70 may be
formed by a fill tube 72 that may be formed as part of one of the
half shells 66, 68. The example fill tube 72 is illustrated as
being formed as part of the second tank half shell 68. The tube 72
may be formed integrally with the half shell 68, or may be formed
separately and bonded to the half shell 68.
[0042] A float 74 is disposed in the tank 64 to allow an indication
of fluid level within the tank 64. The float 74 may also be formed
of plastic. The float 74 is buoyant in water and water-based
mixtures and other liquids used as cleaners. Example float
structures that provide such buoyancy include, but are not limited
to, forming the float 74 as a hollow, sealed shell, or a shell
formed around a core of low-density material, e.g., polystyrene
closed cell foam or a shell that is formed and then filled with low
density material. The float 74 includes a float magnet 76 fixed
thereto. The magnet 76 is disposed proximate to an outer edge of
the float.
[0043] The tank 64 may include a track 78 formed in a first wall 80
of the tank 64. The track 78 is disposed on an inner surface of the
tank 64, i.e., inside of the tank 64. The track 78 may be in the
form of a cylindrical rail 82 formed integral with the wall 80 of
the shell half 66. The track 78 may include a connecting web 84
connecting the rail 82 to the wall 80. The web 84 has a thickness,
i.e., a width, less than a diameter of the rail 82. Each of the
rail 82 and the web 84 may be either solid or hollow.
[0044] The float 74 may have a track groove 86 that receives the
rail 82 for slidable disposition thereon. The float 74 is able to
move up and down freely along the track 78 as the fluid level
changes. The track groove 86 may be complementary in shape to the
track 78, having, for example, an annular portion 88 sized to
provide a slip fit with respect to the rail 82, i.e. with the
annular portion 88 being slightly larger than the rail 82 to allow
the float to freely translate along the rail 82, and an open side
with a gap between opposed groove edges 90 spanning the web 84. The
gap is sized to provide a slip fit with respect to the web 84,
allowing the float 74 to snap onto the track 78 for retention
thereon. The annular portion 88 may extend more than 180 degrees
around a center of the track groove 86 to the groove edges,
allowing retention of the float 74 on the track 78. The float 74
may be slidably disposed on the track 78 by aligning the gap
between the edges 90 with the rail 82 and pressing the float 74
against the rail 82 to snap the float 74 onto the track 78.
Relative elastic deflection between the rail 82 and the edges 90
allows the edges 90 to move around an outer circumference of rail
82 when float 74 is pushed against the rail 82. After the edges 90
have passed a center of the rail 82, the float 74 is retained by
the rail 82.
[0045] In the illustrated embodiments of FIGS. 3-6, the track 78 is
shown as being straight. However, the float 74 may be configured to
accommodate a slight curvature in the track 78 by, for example,
forming the track groove 86 as part of two separate parts, e.g.,
two C-clips (not shown) with a first C-clip proximate to a top of
the float 74 and a second C-clip proximate to a bottom of the float
74. Clearance between the float 74 and the first wall 80 may be
provided by spacing a side of the float 74 between the two C-clips,
i.e., the track groove parts. The space between the C-clips
accommodates an arching of the track 78.
[0046] The tank assembly 12 includes two level sensors, a first
level sensor 92 and a second level sensor 94. Each of the level
sensors 92 and 94 may be Hall effect sensors, i.e.,
magnetically-responsive sensors that generate a signal responsive
to the presence of a magnet. The sensors 92, 94 may have power
supplied to them at all times to allow their operation. The level
sensors 92, 94 are fixed to an outside of a second wall 96 of the
tank 64 at a location associated with the track 78. The first level
sensor 92 is located at a first location associated with a first
level of fluid, i.e., a first fluid volume, e.g., less than half of
a capacity of the tank 64, when the tank 64 is in an installed
orientation. The second level sensor 94 is located at a second
location associated with a second level of fluid, i.e., a second
fluid volume. The second fluid volume is less than the first fluid
volume. The first fluid volume is indicative of an amount of fluid
that may be associated with a first remaining vehicle travel
distance, i.e., the distance the vehicle 13 can travel at the
current rate of washer fluid consumption before the tank assembly
12 is emptied of washer fluid. The second fluid volume of assembly
12 is indicative of an amount of fluid that may be associated with
a second remaining travel distance. The sensors 92, 94 may both be
attached to the second wall 96 via heat stake, sonic weld or highly
bonding glue.
[0047] The float 74 may be disposed in a float chamber 98 of the
tank 64 as illustrated in FIGS. 3 and 4. The chamber 98 may have a
height less than an overall height of the washer fluid tank 64 in
its installed orientation. The first wall 80 and the second wall 96
may form sides of the chamber 98. The chamber 98 must be positioned
high enough and be long enough to accommodate placement of the
sensors 92, 94 thereon at locations allowing indications of the
first and second volumes of the tank assembly 12. The illustrated
chamber 98 incorporates the first wall 80 with the track 78 and the
second wall 96 with the sensors 92, 94. The float is slidably and
non-rotatably disposed on the rail, i.e., the engagement of the
float 74 with the track 78 prevents rotation of the float 74 within
the chamber, maintaining the magnet 76 in a position facing the
second wall 96 as the float translates up and down with the fluid
level. With an arrangement as illustrated in FIGS. 3 and 4, the
float magnet 76 may be placed opposite the groove 86.
Alternatively, the magnet 76 may be placed on a top or a bottom of
the float 74, so long as a part of the magnet 76 is proximate to
the second wall 96, i.e., within a sensing range of the sensors 92,
94 on the second wall. Yet alternatively, the first and second
walls 80, 96 may be at right angles, allowing the magnet 76 to be
located at 90 degrees to the groove 86.
[0048] The sensors 92, 94 may be integrated into the dual level
washer fluid sensor assembly 100. A first connecting strip 102 may
be disposed between, and connect, the first level sensor 92 and the
second level sensor 94. A second connecting strip 104 may be
disposed between, and connect, the second sensor 92 and a sensor
connector 106. The connector 106 may be electronically connected to
each of the sensor 92, 94 by wires (not shown) that may be
incorporated into the strips 102, 104. The connector 106 may
receive a plug (not shown) connecting sensors 92, 94 with
controller 54 through the network 56. The sensors 92, 94, the
connecting strips 102, 104 and the connector 106 may each be bonded
to the wall 96 by any appropriate method or mechanism, e.g., heat
staking, sonic welding, adhesive bonding, etc.
[0049] The dual level washer fluid sensor assembly 100 allows fluid
level sensing without any risk of leaking at the sensor assembly
100 as may occur with a float-type level sensor that passes through
a side of the tank 64. The level sensor assembly 100 may be adapted
to washer fluid tanks of any shape and size.
[0050] Each of the sensors 92, 94 produces a signal, e.g., a Hall
voltage, indicating the presence of the float magnet 76 when the
magnet 76 is in alignment therewith and is within the sensing range
of the sensors 92, 94. The sensing range of one of the sensors 92,
94 is a predetermined distance between the magnet 76 and the sensor
92, 94. The range may be determined as a function of several
factors that may include an expected temperature range,
characteristics of the sensor, and characteristics of the magnet
including a shape of the magnet, a size of the magnet, and a field
strength of the magnet. The controller 54 is programmed to
recognize such signals as indicative of the remaining fluid in the
tank 64 being at the first fluid volume when the first level sensor
92 provides a signal indicating magnetic presence, and as
indicative of the remaining fluid in the tank 64 being at the
second, lower fluid volume when the second level sensor 94 provides
a signal indicating magnetic presence.
[0051] The second tank assembly 14, except as expressly described
herein, has substantially the same structure as the first tank
assembly 12, e.g., the second tank assembly 14 may have just the
one pump 50 and may include the vent 24. The second tank assembly
14 includes the second tank 108. The tank 108 may be substantially
the same as the first tank 64. The second tank 108 may also be
injection molded in multiple parts, and assembled by bonding the
parts together. A second float 110 may be similarly disposed in the
second tank 108. The float 110 may be slidably disposed on a second
track 111, with a second track groove (not shown) receiving the
second track 111. The second float 110 may include a second float
magnet 112. The tank 108 may have its own first wall (not shown)
and a second wall 114, with the second track 111 disposed on an
inside of the first wall, and a second sensor assembly (not shown)
bonded to an outside of the second wall 114. The second sensor
assembly may include just one sensor, e.g., a second or lower level
sensor 116, and a connector and a connecting strip (not shown)
disposed between the connector and the sensor 116. Alternatively,
the second sensor assembly may also include a first level sensor
above the second level sensor 116.
[0052] FIGS. 5 and 6 show an alternative example first tank half
shell 66' illustrating the flexibility of the system 10 in
accommodating a wide variety of tank shapes. Reference numbers used
in FIGS. 5 and 6 correspond to reference numbers used in FIGS. 1-4,
with the reference numbers used in FIGS. 5 and 6 distinguished from
the reference numbers used in FIGS. 1-4 by the use of a prime mark
(') to distinguish the elements.
[0053] FIG. 5 illustrates an inside of the half shell 66'. A float
74' is slidably disposed on a track 78'. The track 78' is formed on
the first wall 80'. The second wall 96' is joined to the first wall
80'. The walls 80' and 96' are substantially perpendicular to each
other. Accordingly, a float magnet 76' may be located on the float
74' at a right angle to a track groove 86' in the float 74'. With
the magnet 76' and the groove 86' so positioned, the magnet 76'
faces the second wall 96'.
[0054] FIG. 6 illustrates an outside of the half shell 66'. A dual
level washer fluid sensor assembly 100' is disposed on an outside
of the second wall 96'. The assembly 100' includes a first level
sensor 92' and a second level sensor 94' connected by a first
connecting strip 102'. A second connecting strip 104' connects the
sensors 92', 94' with a connector 106'. The assembly 100' may vary
from the assembly 100 at least in the distance between the sensors
92', 94' of assembly 100' and between the sensors 92, 94 of
assembly 100.
[0055] Referring to the flow chart of FIG. 7, the system 10 may
operate as follows.
[0056] FIG. 7 illustrates a washer fluid level management process
130 for operating the system 10 of FIG. 1, simplified to facilitate
understanding of the process 130 by not including operation of the
second tank assembly 14. The washer fluid level management process
may be stored in the controller 54. The controller 54 executes the
example steps illustrated in FIG. 7 as described below. A computer
program for executing the process 130 is instantiated in start
block 132, e.g., when movement of the vehicle 13 is initiated, or
when a power-on command is issued, as may be associated with the
vehicle 13 being powered up responsive to an approach or a touch by
a vehicle passenger or operator.
[0057] Next, decision block 134 checks for a signal from the first
level sensor 92, e.g., a Hall voltage, indicating that the float
magnet 76 is substantially aligned with the sensor 92 and the fluid
level is at the first level, i.e., a first volume of fluid. When
the signal from the first level sensor 92 has not been detected,
the process 130 returns to the decision block 134 to continue
checking for the signal from the sensor 92. When the sensor 92
provides a signal indicating that the fluid level is at the first
level, the process 130 moves to process block 136. Process block
136 directs the system 10 to stop the flow of fluid to the
windshield washer nozzle 26 to begin conserving fluid. Process
block 136 may also set a first virtual switch, virtual switch 1
(not shown) within the controller 54 indicative of a first low
level of fluid, i.e., the first fluid volume. The level selected
for the first low level of fluid may be one that is low, but not
critically low. So long as the sensors 32, 40 on which the vehicle
13 depends for navigation are not behind the windshield 28 or
backlite 36, a clean windshield 28 and a clean backlite 36 are not
critical to the continued operation of the vehicle 13 when it is
operating in the autonomous mode.
[0058] The process 130 continues to decision block 138 which checks
for a signal from the second level sensor 94, e.g., a Hall voltage,
indicating that the float magnet 76 is substantially aligned with
the sensor 94 and the fluid level is at the second level, i.e., a
second fluid volume. When the signal from the second level sensor
94 has not been detected, the process 130 moves on to decision
block 140. Decision block 140 assesses whether the vehicle 13 is
within a predetermined time or distance (e.g., two minutes) of a
depot that could provide a refill, and whether the trip is a
time-critical trip (e.g., emergency transport to a hospital). When
the time or distance is greater than the predetermined value, or
the trip is timing critical, the trip is continued and the process
130 cycles back to the decision block 138 to continue checking for
the signal from the sensor 94. When the anticipated time or
distance is less than the predetermined value, and the trip is not
time-critical, then the process 130 moves to process block 142.
[0059] Process block 142 directs the vehicle 13 to the depot for
refilling. Once the tank assembly 12 has been refilled with washer
fluid, the process 130 may continue to process block 143 which
directs the vehicle 13 to continue the trip. The process 130 then
returns to the start block 132 and the condition of sensor 92
stored by the controller 54, i.e., the virtual switch, is reset to
an untriggered condition.
[0060] When the signal from the second level sensor 94 provides a
signal indicating that the fluid level is at the second level, the
process 130 moves to process block 144. Process block 144 may set a
second virtual switch, virtual switch 2 (not shown) within the
controller 54 indicative of a second low level of fluid, i.e., the
second level. The level selected for the second low level of fluid
may be a critically low level, indicating a significantly limited
vehicle operating range. The process 130 moves from process block
144 to decision block 145.
[0061] Decision block 145 determines whether there is sufficient
washer fluid remaining in the tank assembly 12 to complete the trip
by estimating how much fluid will be needed for the rest of the
trip, and comparing it with how much fluid is left in the tank
assembly 12. When the float 74, as indicated by the effect of the
float magnet 76 on the sensor 94, is at the second level, the
remaining volume of fluid is known.
[0062] With GPS data and route planning functionality, controller
54 may determine a value for the remaining trip distance. The
remaining range available with the washer fluid available in the
tank assembly 12 may be calculated based on any one of several
methods. The washer tank assembly 12 may be equipped with a flow
meter (not shown) measuring the quantity of fluid leaving the tank
assembly 12. The controller 54 may use the quantity of fluid
dispensed over a known travel period (e.g., the last 15 minutes) to
calculate a value for the quantity of fluid consumed per unit of
time. And so long as the controller has a value for the distance
traveled over that same period of time, it may calculate a value
for the quantity of fluid consumed per unit of distance. Values for
both the quantity of fluid consumed per unit of distance and the
quantity of fluid consumed per unit of time may change with road
and weather conditions.
[0063] An alternative method of calculating rate of fluid usage is
to take a known volume difference between level 1 and level 2, and
divide it by the number of miles traveled between the first level
and the second level. However the value of volume per unit mile is
calculated, it is used to determine a remaining travel range before
the washer fluid is exhausted. Multiple approaches may be employed
with multiple values for the volume per unit mile being calculated,
and the highest value for the volume of fluid per mile may be
adopted for further calculations. Decision block 145 calculates the
volume of fluid required to complete the current trip based on the
calculated rate of fluid usage. The decision block 145 then
compares the volume in the tank with the volume calculated as
needed to complete the trip.
[0064] When decision block 145 determines that there is a
sufficient volume of fluid remaining to complete the trip, i.e.,
sufficient fluid, the process 130 may move to process block 146.
Process block 146 sets a service notice for the washer fluid to be
refilled on the return of the vehicle 13. Process 130 may then
continue to process block 143 which directs the vehicle 13 to
continue the trip. The process 130 then returns to the start block
132 and the condition of sensors 92, 94 stored by the controller
54, i.e., the virtual switches 1 and 2, may be reset to an
untriggered condition.
[0065] When decision block 145 determines that there is not enough
fluid remaining to complete the trip, the process 130 continues to
process block 142. As per, the above, process block 142 directs the
vehicle 13 to the depot for refilling. Once the tank assembly 12
has been refilled, the process 130 may move on to process block 143
which directs the vehicle 13 to continue the trip. The process 130
then returns to the start block 132 and the condition of sensors
92, 94 stored by the controller 54, i.e., the virtual switches 1
and 2, are reset to an untriggered condition.
[0066] An example tank assembly, a washer system, and method for
using the same have been disclosed.
[0067] As used herein, the adverb "substantially" means that a
shape, structure, measurement, quantity, time, etc. may deviate
from an exact described geometry, distance, measurement, quantity,
time, etc., because of imperfections in materials, machining,
manufacturing, transmission of data, computational speed, etc.
[0068] With regard to the references to ECUs in the present
description, computing devices such as those discussed herein
generally each include instructions executable by one or more
computing devices such as those identified above, and for carrying
out blocks or steps of processes described above. For example,
process blocks discussed above are embodied as computer executable
instructions.
[0069] In general, the computing systems and/or devices described
may employ any of a number of computer operating systems,
including, but by no means limited to, versions and/or varieties of
the Ford Sync.RTM. application, AppLink/Smart Device Link
middleware, the Microsoft Automotive.RTM. operating system, the
Microsoft Windows.RTM. operating system, the Unix operating system
(e.g., the Solaris.RTM. operating system distributed by Oracle
Corporation of Redwood Shores, Calif.), the AIX UNIX operating
system distributed by International Business Machines of Armonk,
N.Y., the Linux operating system, the Mac OSX and iOS operating
systems distributed by Apple Inc. of Cupertino, Calif., the
BlackBerry OS distributed by Blackberry, Ltd. of Waterloo, Canada,
and the Android operating system developed by Google, Inc. and the
Open Handset Alliance, or the QNX.RTM. CAR Platform for
Infotainment offered by QNX Software Systems. Examples of computing
devices include, without limitation, an on-board vehicle computer,
a computer workstation, a server, a desktop, notebook, laptop, or
handheld computer, or some other computing system and/or
device.
[0070] Computing devices generally include computer-executable
instructions, where the instructions may be executable by one or
more computing devices such as those listed above. Computer
executable instructions may be compiled or interpreted from
computer programs created using a variety of programming languages
and/or technologies, including, without limitation, and either
alone or in combination, Java.TM., C, C++, Matlab, Simulink,
Stateflow, Visual Basic, Java Script, Perl, HTML, etc. Some of
these applications may be compiled and executed on a virtual
machine, such as the Java Virtual Machine, the Dalvik virtual
machine, or the like. In general, a processor (e.g., a
microprocessor) receives instructions, e.g., from a memory, a
computer readable medium, etc., and executes these instructions,
thereby performing one or more processes, including one or more of
the processes described herein. Such instructions and other data
may be stored and transmitted using a variety of computer readable
media. A file in a computing device is generally a collection of
data stored on a computer readable medium, such as a storage
medium, a random access memory, etc.
[0071] A computer-readable medium (also referred to as a
processor-readable medium) includes any non-transitory (e.g.,
tangible) medium that participates in providing data (e.g.,
instructions) that may be read by a computer (e.g., by a processor
of a computer). Such a medium may take many forms, including, but
not limited to, non-volatile media and volatile media. Non-volatile
media may include, for example, optical or magnetic disks and other
persistent memory. Volatile media may include, for example, dynamic
random access memory (DRAM), which typically constitutes a main
memory. Such instructions may be transmitted by one or more
transmission media, including coaxial cables, copper wire and fiber
optics, including the wires that comprise a system bus coupled to a
processor of an ECU. Common forms of computer-readable media
include, for example, a floppy disk, a flexible disk, hard disk,
magnetic tape, any other magnetic medium, a CD-ROM, DVD, any other
optical medium, punch cards, paper tape, any other physical medium
with patterns of holes, a RAM, a PROM, an EPROM, a FLASH-EEPROM,
any other memory chip or cartridge, or any other medium from which
a computer can read.
[0072] Databases, data repositories or other data stores described
herein may include various kinds of mechanisms for storing,
accessing, and retrieving various kinds of data, including a
hierarchical database, a set of files in a file system, an
application database in a proprietary format, a relational database
management system (RDBMS), etc. Each such data store is generally
included within a computing device employing a computer operating
system such as one of those mentioned above, and are accessed via a
network in any one or more of a variety of manners. A file system
may be accessible from a computer operating system, and may include
files stored in various formats. An RDBMS generally employs the
Structured Query Language (SQL) in addition to a language for
creating, storing, editing, and executing stored procedures, such
as the PL/SQL language mentioned above.
[0073] In some examples, system elements may be implemented as
computer-readable instructions (e.g., software) on one or more
computing devices (e.g., servers, personal computers, etc.), stored
on computer readable media associated therewith (e.g., disks,
memories, etc.). A computer program product may comprise such
instructions stored on computer readable media for carrying out the
functions described herein.
[0074] With regard to the media, processes, systems, methods,
heuristics, etc. described herein, it should be understood that,
although the steps of such processes, etc. have been described as
occurring according to a certain ordered sequence, such processes
may be practiced with the described steps performed in an order
other than the order described herein. It further should be
understood that certain steps may be performed simultaneously, that
other steps may be added, or that certain steps described herein
may be omitted. In other words, the descriptions of processes
herein are provided for the purpose of illustrating certain
embodiments, and should in no way be construed so as to limit the
claims.
[0075] 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.
* * * * *