U.S. patent number RE47,942 [Application Number 15/700,543] was granted by the patent office on 2020-04-14 for high definition lidar system.
This patent grant is currently assigned to Velodyne Lindar, Inc.. The grantee listed for this patent is Velodyne Lidar, Inc.. Invention is credited to David S. Hall.
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United States Patent |
RE47,942 |
Hall |
April 14, 2020 |
High definition lidar system
Abstract
A LiDAR-based 3-D point cloud measuring system includes a base,
a housing, a plurality of photon transmitters and photon detectors
contained within the housing, a rotary motor that rotates the
housing about the base, and a communication component that allows
transmission of signals generated by the photon detectors to
external components. In several versions of the invention, the
system includes a vertically oriented motherboard, thin circuit
boards such as ceramic hybrids for selectively mounting emitters
and detectors, a conjoined D-shaped lens array, and preferred
firing sequences.
Inventors: |
Hall; David S. (San Jose,
CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Velodyne Lidar, Inc. |
Dover |
DE |
US |
|
|
Assignee: |
Velodyne Lindar, Inc. (San
Jose, CA)
|
Family
ID: |
60934514 |
Appl.
No.: |
15/700,543 |
Filed: |
September 11, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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15180580 |
Jun 13, 2016 |
RE46672 |
|
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11777802 |
Jun 28, 2011 |
7969558 |
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61345505 |
May 17, 2010 |
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60807305 |
Jul 13, 2006 |
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Reissue of: |
13109901 |
May 17, 2011 |
8767190 |
Jul 1, 2014 |
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Reissue of: |
13109901 |
May 17, 2011 |
8767190 |
Jul 1, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01S
7/4817 (20130101); G01S 17/89 (20130101); G01S
7/4811 (20130101); G01S 17/89 (20130101); G01S
7/4813 (20130101); G01S 7/4813 (20130101) |
Current International
Class: |
G01S
7/481 (20060101); G01S 17/89 (20200101) |
Field of
Search: |
;356/5.01,3.01,4.01,4.07,5.09,9,625 ;382/103,105,154
;358/453,475,480 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2177931 |
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Apr 2010 |
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EP |
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2177931 |
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Apr 2016 |
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EP |
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H3-6407 |
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Jan 1991 |
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JP |
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H6-288725 |
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Oct 1994 |
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JP |
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2001-256576 |
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Sep 2001 |
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JP |
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2005-297863 |
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Oct 2005 |
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JP |
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2006-177843 |
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Jul 2006 |
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JP |
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WO 2008/008970 |
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Jan 2008 |
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WO |
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|
Primary Examiner: Whittington; Kenneth
Attorney, Agent or Firm: Goodwin Procter LLP
Parent Case Text
PRIORITY CLAIM .Iadd.AND CROSS-REFERENCES TO RELATED
APPLICATIONS.Iaddend.
This application is a .Iadd.reissue continuation of application
Ser. No. 15/180,580, filed Jun. 13, 2016, which is an application
for reissue of U.S. Pat. No. 8,767,190, issued Jul. 1, 2014, which
claims the benefit of U.S. provisional application Ser. No.
61/345,505 filed May 17, 2010 and which is a
.Iaddend.continuation-in-part of U.S. application Ser. No.
11/777,802, .Iadd.now U.S. Pat. No. 7,969,558, .Iaddend.filed Jul.
13, 2007, .[.and further.]. .Iadd.which .Iaddend.claims the benefit
of U.S. provisional application Ser. No. 60/807,305 filed Jul. 13,
2006.[., and U.S. provisional application Ser. No. 61/345,505 filed
May 17, 2010.].. .Iadd.Notice: more than one reissue application
has been filed for the reissue of U.S. Pat. No. 8,767,190. The
reissue applications are U.S. application Ser. No. 15/180,580,
filed Jun. 13, 2016; and U.S. application Ser. No. 15/700,543 (the
present application), Ser. Nos. 15/700,558, 15/700,571, 15/700,836,
15/700,844, 15/700,959, and 15/700,965, each of which was filed on
Sep. 11, 2017. .Iaddend.The contents of each of the foregoing
applications are hereby incorporated by reference.
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
.[.1. A LiDAR-based sensor system comprising: a base; head
assembly; a rotary component configured to rotate the head assembly
with respect to the base, the rotation of the head assembly
defining an axis of rotation; an electrical motherboard carried in
the head assembly, the motherboard defining a plane and being
positioned substantially parallel to the axis of rotation; a lens
positioned on the head assembly on a first side of the motherboard;
a mirror positioned on the head assembly on a second side of the
motherboard; a plurality of photon transmitters mounted to a
plurality of emitter circuit boards, the plurality of emitter
circuit boards being mounted directly to the motherboard; and a
plurality of detectors mounted to a plurality of detector circuit
boards, the plurality of detector circuit boards being mounted
directly to the motherboard..].
.[.2. The sensor system of claim 1, wherein the lens comprises an
emitter lens and a detector lens, the emitter lens and the detector
lens being positioned adjacent one another; and the mirror
comprises an emitter mirror and a detector mirror; wherein the
emitter mirror is positioned within the head assembly to reflect
light from the plurality of photon transmitters through the emitter
lens, and the detector mirror is positioned within the head to
reflect light received through the detector lens toward the
plurality of detectors..].
.[.3. The sensor system of claim 2, further comprising a unitary
support structure, the motherboard, detector lens, emitter lens,
detector mirror, and emitter mirror all being secured to the
unitary support structure..].
.[.4. The sensor system of claim 2, wherein the plurality of
emitters are oriented to transmit light from the second side of the
motherboard toward the emitter mirror..].
.[.5. The sensor system of claim 4, wherein the motherboard
comprises a central opening, the central opening being positioned
to allow light from the emitters to pass from emitter mirror
through the central opening and toward the emitter lens..].
.[.6. The sensor system of claim 5, wherein the central opening is
further positioned to allow light to pass from the detector lens
through the central opening and toward the detector mirror..].
.[.7. The sensor system of claim 2, wherein the plurality of
emitter circuit boards are secured to the motherboard to form a
first vertical stack..].
.[.8. The sensor system of claim 7, wherein the first vertical
stack of emitter circuit boards forms an angularly fanned
array..].
.[.9. The sensor system of claim 7, wherein the plurality of
detector circuit boards are secured to the motherboard to form a
second vertical stack, the first vertical stack of emitter circuit
boards being positioned substantially parallel to the second
vertical stack of detector circuit boards..].
.[.10. The sensor system of claim 9, wherein the second vertical
stack of detector circuit boards forms an angularly fanned
array..].
.[.11. The sensor system of claim 2, wherein the emitter lens
comprises a first D-shaped lens and the detector lens comprises a
second D-shaped lens, a respective vertical side of each of the
first D-shaped lens and the second D-shaped lens being positioned
closely adjacent one another to form a conjoined D-shaped lens
array..].
.[.12. The sensor system of claim 11, wherein the first D-shaped
lens comprises a first plurality of lenses, and wherein the second
D-shaped lens comprises a second plurality of lenses..].
.[.13. The sensor system of claim 2, wherein the plurality of
emitter circuit boards are secured to the motherboard to form a
first vertical stack, the first vertical stack being divided into
at least two groups of emitters, each of the at least two groups
comprising several emitters from the plurality of emitters such
that the at least two groups form non-overlapping subsets of the
plurality of emitters, the sensor further having a control
component to control the firing of the emitters such that one
emitter is fired at a time, the control component further causing
firing from one of the at least two groups and then the other of
the at least two groups in an alternating fashion..].
.[.14. The sensor system of claim 13, wherein the at least two
groups comprises: a first group forming a first portion of the
first vertical stack and organized sequentially from a first top
position to a first bottom position; and a second group forming a
remaining portion of the first vertical stack organized
sequentially from a second top position to a second bottom
position; whereby the control component causes firing of the
emitters to alternate between the first group and the second group,
and further causes firing within the first group to proceed
sequentially and firing within the second group to proceed
sequentially..].
.[.15. The sensor system of claim 2, wherein the rotary component
further comprises a capacitive coupler..].
.[.16. A LiDAR-based sensor system comprising: a base; head
assembly; a motor configured to rotate the head assembly with
respect to the base, the rotation of the head assembly defining an
axis of rotation; an electrical motherboard carried in the head
assembly; a plurality of photon transmitters mounted to a plurality
of emitter circuit boards, the plurality of emitter circuit boards
being mounted to the motherboard; a plurality of detectors mounted
to a plurality of detector circuit boards, the plurality of
detector circuit boards being mounted to the motherboard; an
emitter mirror supported within the head assembly; a detector
mirror supported within the head assembly; and a conjoined D-shaped
lens assembly, the lens assembly forming an emitter portion and a
detector portion; wherein the motherboard is a unitary component
for mounting the plurality of emitter circuit boards and the
plurality of detector circuit boards, the motherboard being
positioned between the emitter mirror and the detector mirror on a
first side and the lens assembly on the other side, the motherboard
further having an opening to allow light to pass between the lens
assembly and either the detector mirror or the emitter mirror;
whereby light transmitted by one of the plurality of emitters is
reflected from the emitter mirror and passes through the emitter
portion of the lens assembly, and light received by the detector
portion of the lens assembly is reflected by the detector mirror
and received by one of the plurality of detectors..].
.[.17. The sensor system of claim 16, wherein the motherboard
defines a plane that is parallel to the axis of rotation..].
.[.18. The sensor system of claim 17, further comprising: a control
component for causing the firing of the plurality of emitters; and
further wherein there are n emitters in the plurality of emitters,
the n emitters being positioned in a vertical stack from 1 to n,
the plurality of emitters being divided into two groups, including
a first group of emitters from 1 to n/2 and a second group of
emitters from n/2+1 to n; wherein the control component causes the
emitters to fire alternatingly between the first group and the
second group, and to fire sequentially within each group such that
emitter 1 and emitter n/2+1 fire sequentially..].
.Iadd.19. A LiDAR-based sensor system comprising: a base having a
head assembly and a rotary component configured to rotate the head
assembly with respect to the base, the head assembly further having
a circumference spaced apart from an axis of rotation of the head
assembly; a motherboard carried in the head assembly; a lens
positioned on the head assembly along the circumference of the head
assembly; a mirror positioned on the head assembly along the
circumference of the head assembly; a plurality of transmitters
mounted to a plurality of emitter circuit boards carried on the
head assembly for rotation with the head assembly, the plurality of
transmitters positioned to transmit light pulses through the lens;
a plurality of detectors mounted to a plurality of detector circuit
boards carried on the head assembly for rotation with the head
assembly, the plurality of detectors positioned to receive
reflected light pulses from one or more surfaces; a processor
coupled to the plurality of transmitters; and a memory including
processor executable code, wherein the processor executable code,
upon execution by the processor, configures the processor to cause
firing of fewer than the entire plurality of transmitters at a
time..Iaddend.
.Iadd.20. The sensor system of claim 19, wherein the processor is
configured to cause the firing of only one of the plurality of
transmitters at a time..Iaddend.
.Iadd.21. The sensor system of claim 20, wherein the plurality of
transmitters and the plurality of detectors form a plurality of
transmitter-detector pairs, and wherein the processor is configured
to cause only one transmitter-detector pair to be active at any
time..Iaddend.
.Iadd.22. The sensor system of claim 19, wherein each one of the
transmitters from among the plurality of transmitters is physically
adjacent to at least one other of the transmitters from among the
plurality of transmitters, and wherein the processor is configured
to cause the firing of the plurality of transmitters in a
non-adjacent firing order, such that at no time do adjacent
transmitters fire in consecutively in sequence..Iaddend.
.Iadd.23. The sensor system of claim 19 wherein: wherein there are
n transmitters in the plurality of transmitters, the n transmitters
being positioned in a sequence from 1 to n, the plurality of
transmitters being divided into two groups, including a first group
of transmitters from I to n/2 and a second group of transmitters
from n/2+1 to n; and wherein the processor is configured to cause
the transmitters to fire alternatingly between the first group and
the second group, and to fire sequentially within each group such
that transmitter 1 and transmitter n/2+1 fire
sequentially..Iaddend.
.Iadd.24. The sensor system of claim 19, wherein the lens and the
mirror are positioned along the circumference of the head assembly
such that a center of gravity of the head assembly corresponds to
the axis of rotation..Iaddend.
.Iadd.25. The sensor system of claim 19, wherein the head assembly
is configured to rotate at a rotational speed, and wherein the
processor is configured to cause the firing of fewer than the
entire plurality of transmitters according to the rotational
speed..Iaddend.
.Iadd.26. The sensor system of claim 25, wherein the processor is
configured to start the firing of fewer than the entire plurality
of transmitters upon determining that the rotational speed reaches
a threshold..Iaddend.
.Iadd.27. A LiDAR-based sensor system comprising: a base; a head
assembly; a rotary component configured to rotate the head assembly
with respect to the base along an axis of rotation; a motherboard
carried in the head assembly; a lens positioned at a periphery of
the head assembly; a mirror positioned at the periphery of the head
assembly; a plurality of photon transmitters mounted to a plurality
of emitter circuit boards, the plurality of emitter circuit boards
mounted to the motherboard; a plurality of detectors mounted to a
plurality of detector circuit boards, the plurality of detector
circuit boards mounted to the motherboard; a processor coupled to
the plurality of photon transmitters; and a memory including
processor executable code, wherein the processor executable code,
upon execution by the processor, configures the processor to cause
firing of fewer than the entire plurality of photon transmitters at
a time..Iaddend.
.Iadd.28. The sensor system of claim 27, wherein the processor is
configured to cause the firing of only one photon transmitter at a
time..Iaddend.
.Iadd.29. The sensor system of claim 28, wherein the plurality of
photon transmitters and the plurality of detectors form a plurality
of transmitter-detector pairs, and wherein only one
transmitter-detector pair is active at any time..Iaddend.
.Iadd.30. The sensor system of claim 27, wherein the processor is
configured to cause the firing of the photon transmitters in a
non-adjacent firing order, such that at no time do adjacent photon
transmitters fire in sequence..Iaddend.
.Iadd.31. The sensor system of claim 27, wherein: the plurality of
transmitters includes n transmitters positioned in a sequence from
1 to n, the n transmitters divided into two groups, including a
first group of transmitters from 1 to n/2 and a second group of
transmitters from n/2+1 to n; and wherein the processor is
configured to cause the transmitters to fire alternatingly between
the first group and the second group, and to fire sequentially
within each group such that transmitter I and transmitter n/2+1
fire sequentially..Iaddend.
.Iadd.32. The sensor system of claim 27, wherein the motherboard,
the rotary component, the lens, and the mirror are enclosed within
the head assembly, and wherein the lens and the mirror are
positioned at the periphery of the head assembly such that a center
of gravity of the head assembly corresponds to the axis of rotation
of the rotary component..Iaddend.
.Iadd.33. The sensor system of claim 27, wherein the rotary
component is configured to rotate at a rotational speed, and
wherein the processor is configured to cause the firing of fewer
than the entire plurality of photon transmitters according to the
rotational speed..Iaddend.
.Iadd.34. The sensor system of claim 33, wherein the processor is
configured to start the firing of fewer than the entire plurality
of transmitters upon determining that the rotational speed reaches
a threshold..Iaddend.
Description
BACKGROUND OF THE INVENTION
The present invention concerns the use of light pulses that are
transmitted, reflected from external objects, and received by a
detector to locate the objects in the field of view of the
transmitter. By pulsing a laser emitter and receiving the
reflection, the time required for the pulse of light to return to
the detector can be measured, thereby allowing a calculation of the
distance between the emitter and the object from which the pulse
was reflected.
When multiple pulses are emitted in rapid succession, and the
direction of those emissions is varied, each distance measurement
can be considered a pixel, and a collection of pixels emitted and
captured in rapid succession (called a "point cloud") can be
rendered as an image or analyzed for other reasons such as
detecting obstacles. Viewers that render these point clouds can
manipulate the view to give the appearance of a 3-D image.
In co-pending application Ser. No. 11/777,802, the applicant
described a variety of systems for use in creating such point cloud
images using Laser Imaging Detection and Ranging (LiDAR). In one
version, the LiDAR system was used for terrain mapping and obstacle
detection, and incorporated as a sensor for an autonomous vehicle.
An exemplary LiDAR system included eight assemblies of eight lasers
each as shown in FIG. 1, or two assemblies of 32 lasers each
forming a 64-element LiDAR system as shown in FIG. 2. Yet other
numbers of lasers or detectors are possible, and in general the
LiDAR was employed in an assembly configured to rotate at a high
rate of speed in order to capture a high number of reflected pulses
in a full circle around the LiDAR sensor.
The preferred examples of the present invention described further
below build on the inventor's prior work as described above,
incorporating several improvements to reduce the overall size and
weight of the sensor, provide better balance, reduce crosstalk and
parallax, and provide other advantages.
SUMMARY OF THE INVENTION
The present invention provides a LiDAR-based 3-D point cloud
measuring system. An example system includes a base, a housing, a
plurality of photon transmitters and photon detectors contained
within the housing, a rotary motor that rotates the housing about
the base, and a communication component that allows transmission of
signals generated by the photon detectors to external
components.
In one version of the invention, the system provides 32
emitter/detector pairs aligned along a vertical axis within a
housing that spins to provide a 360 degree field of view. The
emitters may be aligned along a first axis, with the detectors
aligned along a second axis adjacent to the first.
In a preferred implementation, the emitters and detectors are
mounted on thin circuit boards such as ceramic hybrid boards
allowing for installation on a vertical motherboard for a vertical
configuration, improved alignment, and other advantages. The
motherboard, in one version is formed with a hole in which the
emitters fire rearward into a mirror, reflecting the emitted light
through the hole and through lenses adjacent the motherboard.
In certain configurations, the system employs a conjoint lens
system that reduces or eliminates the parallax problem that may
arise with the use of separate emitter and detector optics.
In still further examples of the invention, the emitters fire in a
non-adjacent pattern, and most preferably in a pattern in which
sequentially fired lasers are physically distant from one another
in order to reduce the likelihood of crosstalk.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred and alternative embodiments of the present invention are
described in detail below with reference to the following
drawings:
FIG. 1 is a front view of a rotating LiDAR system.
FIG. 2 is a perspective view of an alternate LiDAR system.
FIG. 3 is a perspective view of a preferred LiDAR system, showing
an exemplary field of view of the laser emitters.
FIG. 4 is a side view of the preferred LiDAR system of FIG. 3.
FIG. 5 is a side view of the LiDAR system in accordance with FIG.
4, shown with the housing removed.
FIG. 6 is a perspective view of a hybrid containing a preferred
detector.
FIG. 7 is a perspective view of a hybrid containing a preferred
emitter.
FIG. 8 is a back perspective view of the LiDAR system as shown in
FIG. 5.
FIG. 9 is a top perspective view of the LiDAR system as shown in
FIG. 5.
FIG. 10 is an exemplary view of a LiDAR system with a potential
parallax problem.
FIG. 11 is an exemplary front view of a lens assembly.
FIG. 12 is a sectional view of a lens assembly, taken along line
A-A in FIG. 11.
FIG. 13 is a sectional view of an alternate lens assembly, taken
along line A-A in FIG. 11.
FIG. 14 is a representative view of a conjoined D-shaped lens
solving the parallax problem of FIG. 10.
FIG. 15 is a front view of the LiDAR system as shown in FIG. 5.
FIG. 16 is an exemplary view of a rotary coupler for coupling a
housing to a rotating head assembly.
FIG. 17 is an illustration of a potential crosstalk problem.
FIG. 18 is an illustration of a further potential crosstalk
problem.
.Iadd.FIG. 19 is an illustration of an example controller coupled
to a plurality of transmitters and a plurality of
detectors..Iaddend.
.Iadd.FIG. 20 is an illustration of a process provided by an
example embodiment..Iaddend.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Exemplary LiDAR systems are shown in FIGS. 1 and 2. In each case,
.Iadd.as shown in FIG. 20, .Iaddend.a rotating housing .Iadd.201
.Iaddend.fires light pulses .Iadd.202 .Iaddend.that reflect from
objects so that the return reflections may be detected by detectors
within the rotating housing. By rotating the housing, the system
provides a 360-degree horizontal field of view (FOV) and, depending
on the number and orientation of lasers within the housing, a
desired vertical field of view. The system is typically mounted on
the top center of a vehicle, giving it a clear view in all
directions, and rotates at a rate of about 10 Hz (600 RPM), thereby
providing a high point cloud refresh rate, such high rate being
advantageous for autonomous navigation at higher speeds. In other
versions, the spin rate is within a range of about 5 to 20 Hz
(300-1200 RPM). At this configuration, the system can collect
approximately 2.56 million time of flight (TOF) distance points per
second. The system therefore provides the unique combination of 360
degree FOV, high point cloud density, and high refresh rate. The
standard deviation of TOF distance measurements is equal to or less
than 2 cm. The LiDAR system may incorporate an inertial navigation
system (INS) sensor system mounted on it to report x, y, z
deviations and pitch, roll, and yaw of the unit that is used by
navigational computers to correct for these deviations.
Through the use of DSP a dynamic power feature allows the system to
increase the intensity of the laser emitters if a clear terrain
reflection is not obtained by photo detectors (whether due to
reflective surface, weather, dust, distance, or other reasons), and
to reduce power to the laser emitters for laser life and safety
reasons if a strong reflection signal is detected by photo
detectors. A direct benefit of this feature is that the LiDAR
system is capable of seeing through fog, dust, and heavy rain by
increasing laser power dynamically and ignoring early reflections.
The unit also has the capability to receive and decipher multiple
returns from a single laser emission through digitization and
analysis of the waveform generated by the detector as the signal
generated from the emitter returns.
The LiDAR systems of FIGS. 1 and 2 report data in the form of range
and intensity information via Ethernet (or similar output) to a
master navigational system. Using standard trigonometry, the range
data is converted into x and y coordinates and a height value. The
height value can be corrected for the vehicle's pitch and roll so
the resulting map is with reference to the horizontal plane of the
vehicle. The map is then "moved" in concert with the vehicle's
forward or turning motion. Thus, the sensor's input is cumulative
and forms an ultra-high-density profile map of the surrounding
environment.
This highly detailed terrain map is then used to calculate obstacle
avoidance vectors if required and to determine the maximum
allowable speed given the terrain ahead. The LiDAR system
identifies of size and distance of objects in view, including the
vertical position and contour of a road surface. The anticipated
offset of the vehicle from a straight, level path, either vertical
or horizontal, at different distances is translated into the
G-force that the vehicle will be subject to when following the
proposed path at the current speed. That information can be used to
determine the maximum speed that the vehicle should be traveling,
and acceleration or braking commands are issued accordingly. In all
cases the software seeks the best available road surface (and thus
the best possible speed) still within the boundaries of a global
positioning system (GPS) waypoint being traversed.
One version of the inventor's prior system as illustrated in FIG. 1
includes 64 emitter/detector (i.e. laser diode/photo diode) pairs
divided into eight groups of eight. The system shown in FIG. 2 also
includes 64 emitter/detector pairs, but in a configuration of 2
assemblies of 32 pairs. It is also possible to "share" a single
detector among several lasers by focusing several detection regions
onto a single detector, or by using a single, large detector. By
firing a single laser at a time, there would be no ambiguity as to
which laser is responsible for a return signal. Conversely, one
could also sub-divide a single laser beam into several smaller
beams. Each beam would be focused onto its own detector. In any
event, such systems are still considered emitter-detector
pairs.
In the versions as illustrated in FIGS. 1 and 2, the laser diode is
preferably an OSRAM 905 nm emitter, and the photo diode is
preferably an Avalanche variety. More particularly, in the
preferred version each one of the detectors is an avalanche
photodiode detector. The lenses are preferably UV treated to block
sunlight, or employ a separate UV lens filter in the optical path.
Each pair is preferably physically aligned in 1/3.degree.
increments, ranging from approximately 2.degree. above horizontal
to approximately 24.degree. below horizontal. .[.Each.]. .Iadd.As
shown in FIG. 19, each .Iaddend.of the .[.emitter/detector.].
.Iadd.emitter 192/detector 193 .Iaddend.pairs are controlled by
.Iadd.a controller 191, such as .Iaddend.one or more DSPs .[.(.].
or, in some versions, field programmable gate arrays, or FPGAs, or
other microprocessor.[.).]., which determines when they will fire,
determines the intensity of the firing based on the previous
return, records the time-of-flight, calculates height data based
time-of-flight and angular alignment of each pair. Results,
including multiple returns if any, are transmitted via Ethernet to
the master navigational computer via a rotary coupling.
.[.It.]. .Iadd.As shown in FIG. 20, it .Iaddend.is also
advantageous to fire only several lasers, or preferably just one,
at a time .Iadd.202.Iaddend.. This is because of naturally
occurring crosstalk, or system blinding that occurs when the laser
beam encounters a retroreflector. Such retroreflectors are commonly
used along the roadways. A single beam at a time system is thus
resistant to retroreflector blinding, while a flash system could
suffer severe image degradation as a result.
In addition to crosstalk concerns, firing single lasers at once
while rotating at a high rate facilitates eye safety. The high
powered lasers used with the present preferred versions of the
invention would require protective eyewear if the system was used
in a stationary fashion. Rotation of the system and firing fewer
lasers at once for brief pulses allows high powered lasers to be
used while still meeting eye safety requirements that do not
require protective eyewear. In accordance with this aspect of the
invention, the system employs a control component that does not
allow the emitters to fire until the head has reached a desired
minimal rotation speed.
Another advantage of firing only a small number of lasers at a time
is the ability to share, or multiplex, the detection circuitry
among several detectors. Since the detection circuitry consists of
high speed Analog to Digital Converters (ADCs), such as those made
by National Semiconductor, considerable cost savings can be had by
minimizing the use of these expensive components.
In the preferred embodiment, the detectors are power cycled, such
that only the desired detector is powered up at any one time. Then
the signals can simply be multiplexed together. An additional
benefit of power-cycling the detectors is that total system power
consumption is reduced, and the detectors therefore run cooler and
are therefore more sensitive.
A simple DC motor controller driving a high reliability brushed or
brushless motor controls the rotation of the emitter/detectors. A
rotary encoder feeds rotational position to the DSPs (or other
microprocessor) that use the position data to determine firing
sequence. Software and physical fail-safes ensure that no firing
takes place until the system is rotating at a minimum RPM.
FIG. 2 illustrates a perspective view of a 64 emitter/detector pair
LiDAR component 150. The component 150 includes a housing 152 that
is opened on one side for receiving a first LiDAR system 154
located above a second LiDAR system 156. The second LiDAR system
156 is positioned to have line of sight with a greater angle
relative to horizontal than the first LiDAR system 154. The housing
152 is mounted over a base housing section 158.
The LiDAR system of FIG. 2 includes a magnetic rotor and stator. A
rotary coupling, such as a three-conductor Mercotac model 305,
passes through the center of the base 158 and the rotor. The three
conductors facilitated by the rotary coupling are power, signal,
and ground. A bearing mounts on the rotary coupling. A rotary
encoder has one part mounted on the rotary coupling and another
part mounted on the base section 158 of the housing 152. The rotary
encoder, such as a U.S. Digital Model number E65-1000-750-I-PKG1
provides information regarding to rotary position of the housing
152. The magnetic rotor and stator cause rotary motion of the base
section 158 and thus the housing 152 about the rotary coupling.
The version described below with reference to FIGS. 3-16 is
generally referred to as an High Definition LiDAR 32E (HDL-32E) and
operates on the same foundational principles as the sensors of
FIGS. 1 and 2 in that a plurality (in this embodiment up to 32) of
laser emitter/detector pairs are aligned along a vertical axis with
the entire head spinning to provide a 360 degrees horizontal field
of view (FOV). Each laser issues light pulses (in this version, 5
ns pulses) that are analyzed for time-of-flight distance
information (called a "distance pixel" or "return"). Like the
system of FIG. 2, the system reports returns in Ethernet packets,
providing both distance and intensity (i.e. the relative amount of
light received back from the emitter) information for each return.
The sample system reports approximately 700,000 points per second.
While all or any subset of the features described above with
respect to FIGS. 1 and 2 may be incorporated into the version
described below with respect to FIGS. 3-16, alternate embodiments
of the invention may optionally include the additional aspects as
described in detail below.
In a preferred version as illustrated in FIG. 3, the cylindrical
sensor head 10 is about 3.5 inches in diameter and the unit has an
overall height of 5.6 inches and weighs about 2.4 pounds. By
contrast, the HDL-64E (shown in FIG. 2) is 8 inches in diameter by
approximately one foot tall, and weighs about 29 pounds. This
reduction in size is the result of several inventive improvements,
as described more fully below.
The sample embodiment of FIG. 3 can be built with a variable number
of lasers, aligned over a vertical FOV 12 of +10 to -30 degrees as
best seen in FIG. 4. The vertical FOV may be made larger or
smaller, as desired, by adjusting the number or orientation of the
emitters and detectors. When using the emitters as described and
orienting them as described, the range is approximately 100 meters.
The head 10 is mounted on a fixed platform 14 having a motor
configured such that it preferably spins at a rate of 5 Hz to 20 Hz
(300-1200 RPM). The sample system uses 905 nm laser diodes
(although other frequencies such as 1550 nm could be used) and is
Class 1 eye safe.
FIG. 5 illustrates the same version as shown in FIGS. 3 and 4,
though without the outer housing covering the internal components.
In general, and as discussed more fully below, the system includes
a main motherboard 20 supporting a plurality of detector hybrids 32
and emitter hybrids (not visible in FIG. 5). The emitters fire back
toward the rear of the system, where the pulses are reflected from
a mirror and then are directed through a lens 50. Return pulses
pass through a lens, are reflected by a mirror 40, then directed to
the detectors incorporated into the hybrids 32. The motherboard 20
and mirror 40 are mounted to a common frame 22 providing common
support and facilitating alignment.
The hybrids 32 are mounted to the motherboard in a fan pattern that
is organized about a central axis. In the version as shown, 32
hybrids are used in a pattern to create a field of view extending
10 degrees above and 30 degrees below the horizon and therefore the
central axis extends above and below the ninth board 38, with 8
boards above and 23 boards below the central axis. In one version,
each successive board is inclined an additional one and one-third
degree with respect to the next adjacent board. The desired
incremental and overall inclination may be varied depending on the
number of hybrids used, the geometry of the mirrors and lenses, and
the desired range of the system.
One of the features allowing for compact size and improved
performance of the version of FIG. 3 is the use of thin circuit
boards such as ceramic hybrid boards for each of the emitters and
detectors. An exemplary detector circuit board 32 is shown in FIG.
6; an exemplary emitter circuit board 30 is shown in FIG. 7. In the
preferred example, the thin circuit boards are in the form of
ceramic hybrid boards that are about 0.015 inches thick, with only
one emitter mounted on each emitter board, and only one detector
mounted on each detector board. In other versions the thin circuit
boards may be formed from other materials or structures instead of
being configured as ceramic hybrids.
One of the advantages of mounting emitters and detectors on
individual hybrid boards is the ability to then secure the
individual hybrid boards to the motherboard in a vertically aligned
configuration. In the illustrated version, the detectors are
positioned in a first vertical alignment along a first vertical
axis while the emitters are positioned in a second vertical
alignment along a second vertical axis, with the first and second
vertical axes being parallel and next to one another. Thus, as best
seen in FIGS. 5 and 8, the hybrid boards carrying the emitters and
detectors are mounted in vertical stacks that allow the sensor head
to have a smaller diameter than a differently configured sensor
having emitters and detectors positioned about the circumference of
the system. Accordingly, the configuration reduces the overall size
and requires less energy for spinning by moving more of the weight
toward the center of the sensor.
As further shown in FIG. 8, the preferred version incorporates a
plurality of detectors (in this case, 32 of them) mounted to an
equal number of detector hybrids 32. The system likewise has the
same number of emitters mounted to an equal number of emitter
hybrids 30. In the preferred version, the system therefore has one
emitter per hybrid and one detector per hybrid. In other versions
this may be varied, for example to incorporate multiple emitters or
detectors on a single hybrid. The emitter and detector hybrids are
connected to a common motherboard 20, which is supported by a frame
22. The motherboard has a central opening 24 that is positioned to
allow emitted and received pulses to pass through the motherboard.
Because the lenses are positioned over the middle of the
motherboard, the central opening is configured to be adjacent the
lenses to allow light to pass through the portion of the
motherboard that is next to the lenses.
The density of emitter/detector pairs populated along the vertical
FOV is intentionally variable. While 32 pairs of emitters and
detectors are shown in the illustrated versions, the use of hybrids
and a motherboard allows for a reduction in the number of emitters
and detectors by simply removing or not installing any desired
number of emitter/detector pairs. This variation of the invention
cuts down on the number vertical lines the sensor produces, and
thus reduce cost. It is feasible that just a few emitter/detector
pairs will accomplish the goals of certain autonomous vehicles or
mapping applications. For some uses increased density is desirable
to facilitate seeing objects at further distances and with more
vertical resolution. Other uses exploit the fact that there is a
direct relationship between the number of emitter detector pairs
and sensor cost, and do not need the full spread of vertical lasers
to accomplish their sensor goals.
Alternatively, multiple emitters and detectors can be designed and
mounted onto the hybrid boards at slightly different vertical
angles, thus increasing the density of vertical FOV coverage in the
same footprint. If, for example, two emitters and two detectors
were mounted on each of the hybrids shown in FIGS. 6 and 7 with
slight vertical offsets, the design would incorporate 64 emitters
and detectors rather than 32. This example design describes two
emitters and detectors mounted per board, but there is no practical
limit to the number of emitters and detectors that may be mounted
on a single board. The increased number of emitters and detectors
may be used to increase the field of view by adjusting the relative
orientation, or may be used to increase the density of points
obtained within the same field of view.
Another design feature of the preferred version is the vertical
motherboard on which the main electronics that control the firing
of the lasers and the capturing of returns are located. As noted
above, the motherboard is mounted vertically, defining a plane that
is preferably parallel to the central axis 13 (see FIG. 3) about
which the system will rotate. While the motherboard is preferably
parallel to this axis of rotation, it may be inclined toward a
horizontal plane by as much as 30 degrees and still be considered
substantially vertical in orientation. The emitter and detector
hybrid boards are aligned and soldered directly to this vertical
motherboard, thus providing for small overall head size and
increased reliability due to the omission of connectors that
connect the laser boards with the motherboard. This board is
mechanically self-supported, mounted to a frame 22 that fixes it
rigidly in position in a vertical orientation so that it spins with
the rotating sensor head. The insertion of the hybrid boards can be
automated for easy assembly. Prior art sensors exclusively employ
motherboard design requiring connectors and cables between the
emitters and detectors and the motherboard. The positioning and
configuration of the motherboard as shown overcomes these
problems.
Another feature of the vertical motherboard design is its proximity
inside the sensor head. In order to optimize space, the motherboard
is positioned between the mirror and the lenses, as best seen in
FIG. 9. Thus, as shown, the sensor head includes one or more lenses
50, 52 supported within a lens frame 54 positioned at a front side
of the sensor head. One or more mirrors 40, 42 are positioned at
the opposite side of the sensor head and mounted to the frame 22.
In the illustrated version, separate mirrors 40, 42 are used for
the emitter and detectors, respectively. Most preferably, the frame
22 is a unitary frame formed from a single piece of material that
supports the motherboard and the mirrors.
This configuration allows the hybrid emitters to fire rearward into
the first mirror 40, wherein the light then reflects off the mirror
and travels through the hole 24 in the motherboard 20, through the
lens 50 and so that the emitted light 60 travels out to the target
70. This configuration further increases the net focal length of
the light path while retaining small size. Likewise the returning
light 62 passes through the detector lens 52, through the hole 24
in the motherboard to the opposite mirror 52 and is reflected into
the corresponding detector.
Another benefit of the vertical motherboard design is that it
facilitates the goal of balancing the sensor head both statically
and dynamically to avoid shimmy and vibration during operation.
Most preferably, the various components are positioned to allow a
near-balanced condition upon initial assembly that requires a
minimum of final static and dynamic balancing counterweights. As
best seen in FIG. 9, this balancing is obtained by positioning
major portions of components about the circumference of the sensor
head. More specifically, the lenses and frame are on one side while
the mirrors and a generally T-shaped portion of the frame is
diametrically opposite the lenses, with the mirrors and rearward
portion of the frame configured to have a weight that is about
equal to that of the lenses and lens frame. Likewise, the emitter
and detector hybrids are carried on diametrically opposite sides of
the sensor head, positioned at about a 90 degree offset with
respect to the lens and mirror diameter. The motherboard is nearly
along a diameter, positioned to counter balance the weight of the
other components, such that the center of gravity is at the center
of rotation defined by the center of the base 80.
When the present invention is incorporated into an autonomous
navigation or mobile mapping vehicle, GPS and inertial sensors are
often included to locate the vehicle in space and correct for
normal vehicle motion. Inertial sensors often include gyros, such
as fiber optic gyros (FOG), and accelerometers. In one embodiment,
there is a 6-axis inertial sensor system mounted in the LiDAR base
and the signals from the gyros and accelerometers are output along
with the LiDAR distance and intensity data.
The separate location of emitters' and detectors' optical paths can
create a parallax problem. When the emitters and detectors are
separated by a finite distance there always exists a "blind" region
nearest to the sensor in which objects cannot be illuminated or
detected. Likewise, at long range the emitter's laser light becomes
misaligned with its corresponding detector and creates a similar
blind spot. The parallax problem is best seen with reference to
FIG. 10. A representative emitter 170 transmits a light signal
through a lens 172, with the propagated light signal traveling
outward and toward a target in the distance. Light reflected from a
target may return through a second lens 162 and onward toward a
detector 160. The nonparallel orientation of the emitter and
detector, however, creates nonparallel light emitter and detector
paths. Consequently, there is a near blind spot 180 adjacent the
system and a far blind spot 184 more distant from the system. In
either of the two blind spots, light reflecting from an object will
return along a path that cannot be received by the detector. The
near blind spot extends for a distance "A" in front of the system,
while the far blind spot extends in the region of distance "C"
beyond the system. Between the two blind spots, in a distance
defined by "B", the system will see an object in that light
reflected from the object can return along a path that can be
detected. Even within region B, however, there is a "sweet spot"
182 defined by the straight line paths of travel from the emitter
and to the detector. For the sample embodiment shown in FIGS. 1 and
2 the "sweet spot" 182 for parallax alignment is approximately 100
feet from the centerline of the sensor. Inside of about 10 feet the
emitter's light misses its corresponding detector entirely, shown
at 180, and beyond approximately 240 feet, shown at 184, the signal
becomes weak due to the misalignment of the emitter and detector in
the opposite direction.
This effect can be alleviated in one version of the invention by
having two "D"-shaped lenses 50, 52 (see FIG. 15), constructed for
the emitter and detector, and having these two lenses attached to
each other with a minimal gap in between. The close proximity of
the conjoint lens system, best seen in FIG. 14, reduces the "blind"
region to near zero, as shown by the parallel nature of the
emitter's light 60 and detector's light path 62.
Due to the complex nature of the optical propagation in lenses, a
lens array is usually needed to correct for various aberrations
that are commonly associated with any optical design. For the
purpose of constructing a conjoint lens system to overcome the
parallax problem described with respect to FIG. 10, it is useful to
have the first surface of the lens array being the largest pupil;
that is, the optical rays entering the lens system should bend
towards the center.
FIG. 11 illustrates a front view of a lens array 50. Though
indicated as the emitter lens array, it may also be illustrative of
the detector lens array as well. In order to form a D-shaped lens,
an edge 51 of the otherwise circular lens is cut away from the
lens, removing a left edge 120 of the otherwise circular lens. The
resulting lens is somewhat D-shaped, having a vertical left edge.
The use of a D-shaped lens array is advantageous in that D-shaped
lens arrays for the emitter and detector may be placed back-to-back
to form "conjoined" D-shape lens arrays as best seen in FIG. 15.
Placing the vertical edges of the D-shapes adjacent one another
allows the otherwise circular lenses to be much closer to one
another than would be the case if using circular lenses which would
only allow for tangential contact between the lens arrays.
The creation of D-shaped lenses and the use of a conjoined pair of
D-shaped lens arrays, however, brings a potential signal loss. FIG.
12 illustrates a correct design of the lens array, shown in
sectional view taken along lines A-A from FIG. 11. In this
illustration the lens array includes a first lens 113, a second
lens 111, and a third lens 112. The input rays 100 always bend
towards the center in this lens array. Consequently, when a
D-shaped cut is made (that is, cutting off a portion of one side of
each of the lenses in the area indicated by the shaded region 120),
there is no loss of light. As the shaded region indicates, all of
the light entering the first lens 113 travels through the entire
lens array to the mirror.
FIG. 13 illustrates an incorrect design having a similar array of
three lenses 110, 111, 112. In this case, the front lens 110 is
differently shaped and some of the input light rays 100 bend away
from the center as they travel through the front lens. A cut
through the ends of one side of this lens array would result in the
loss of some of the light entering the array, as indicated in the
shaded region 120 in FIG. 12.
By configuring the lenses in an ideal fashion as illustrated in
FIG. 12, a portion of each side of the lens array may be cut in the
form of a D-shape. This creates a straight edge along the sides of
each lens in the array, allowing the straight sides of the D's
forming each lens array to be positioned closely adjacent one
another. In this sense, the term "closely adjacent" is understood
to mean either in contact with one another or positioned such that
the center of the lenses are closer to one another than they could
be without the D-shaped cut. As best see in FIG. 15, the two lens
arrays 50, 52 are positioned closely adjacent one another with the
straight sides back-to-back to form conjoined D-shaped lens arrays.
As described above, a first lens array 50 serves as the emitter
lens array while the adjacent second lens array 52 serves as the
detector lens array.
FIG. 14 illustrates an advantage of the conjoint D-shaped lens
design, particularly in how it overcomes the parallax problem
illustrated in FIG. 10. In this case, light emerging from the
emitter 170 is directed to a first D-shaped lens 50. Most
preferably, the emitter is oriented to direct its light path toward
a position just inward of the straight side edge of the D-shape.
Because of the lens array configuration of the type described in
FIG. 12, the light emerges from the first lens 50 in a straight
line 60 that can be directed radially away from the sensor head.
Likewise, light reflected from the distant object will return along
a return path 62 that is parallel to the emitter light path. The
closely parallel return path will travel through the second,
adjacent conjoined D lens array 52, entering the lens array at a
position just inward of the straight side edge of the D-shape,
where it is then directed to the detector 160. Consequently, there
is no blind spot as with conventional lenses and the parallax
problem is resolved.
Another unique design consideration for the preferred
implementation addresses the need to transfer power and signal up
to the head, and receive signal and offer grounding down from the
head. Off the shelf mercury-based rotary couplers are too
unreliable and too big for this problem. In one embodiment, shown
in FIG. 16, the use of a rotary transformer 145 enables sending
power up to the head, and the use of a capacitive coupler 140 down
from the head to accommodate these requirements. A phase modulation
scheme allows for communication to the head from the base using
serial commands in order to instruct the head to limit horizontal
field of view, fire all lasers at full power, update its firmware,
and other commands.
It is also desired to have the distance returns of the LiDAR
scanner be as accurate as possible and be free of spurious images
or returns. Firing multiple lasers at once can create a crosstalk
condition where the light emitted from one laser inadvertently is
detected by the detector of another laser, thus giving a false
return. Thus, with reference to FIG. 17, if emitters E1 through E4
all fire at once, their returns would be intended to be received by
emitters D1 through D4. But depending on the positioning and
configuration of the object from which the light returns, light
from one of the emitters may be directed to the wrong detector. For
example, as indicated in FIG. 17, light from emitter E1 may end up
directed to detector D3, as indicated by the dotted line return
path. This would be an invalid return, and the system would
erroneously associate it with light sent from emitter E3, thereby
creating a faulty pixel in the point cloud.
A similar error can occur if adjacent lasers are fired in a
sequential fashion. Thus, with reference to FIG. 16, firing a
single emitter E1 may result in light being detected at detector D2
rather than D1. This may most commonly occur when light from
emitter E1 travels beyond the true range of the sensor but is
reflected from a particularly reflective object, such as a stop
sign covered with reflective paint. The firing of adjacent emitters
in order makes this form of cross-talk more likely.
In accordance with a preferred version of the invention, the
emitters are fired in a non-adjacent single laser firing order.
This means that only one emitter detector pair is active at any
given time, and at no time do adjacent emitters and detectors fire
in sequence. Most preferably there is as much distance as possible
between the emitters that are fired in order. Thus, if there are 32
emitters in a vertical stack, the emitters would be assigned labels
E1 representing the top-most emitter and then sequentially numbered
through E32 representing the bottom emitter in the stack. Emitter
E1 (at the top) would be fired first, followed by emitter E17 (in
the middle of the stack), then E2, E18, E3, E19, and so on, ending
with E16 and E32 before starting over again at the beginning This
pattern begins with the top emitter and the middle emitter,
dividing the stack into two groups. It then alternates firing one
from each group, moving from the top of each half-stack and
proceeding sequentially down each half-stack of emitters in an this
alternating fashion and then repeating. This pattern ensures the
largest possible distance between fired lasers, thereby reducing
the chance of crosstalk.
While the preferred embodiment of the invention has been
illustrated and described, as noted above, many changes can be made
without departing from the spirit and scope of the invention.
Accordingly, the scope of the invention is not limited by the
disclosure of the preferred embodiment. Instead, the invention
should be determined entirely by reference to the claims that
follow.
* * * * *