Mechanical adjustment of main light modules on fictitious rotation axes

Abstract

A motor vehicle headlight (101) having a headlight housing (102) and a light module (10) movably arranged therein for generating a predetermined light distribution in a light exit direction (103) of the headlight (101), comprising a first frame (16) which is movable relative to the headlight housing (102) about a first axis of rotation (18), and a second frame (20) which is movable relative to the first frame (16) about a second axis of rotation (22) and to which the light module (10) is fastened, wherein the first axis of rotation (18) and the second axis of rotation (22) intersect one another or are arranged skewed relative to one another, characterized in that a curved guide (24) is provided between the first frame (16) and the second frame (20), which is designed to enable a relative movement between the second frame (20) and the first frame (16) on a curved path (26; 32) about the second axis of rotation (22).

Description

[0001] The present invention relates to a motor vehicle headlight with a headlight housing and a light module movably arranged therein for generating a predetermined light distribution in a light exit direction of the headlight. The headlight comprises a first frame, which is movable relative to the headlight housing about a first axis of rotation, and a second frame, which is movable relative to the first frame about a second axis of rotation and to which the light module is fastened. The first axis of rotation and the second axis of rotation intersect one another or are arranged skewed relative to one another. In this context, skewed means that the two axes of rotation are independent of one another and do not necessarily intersect.

[0002] The invention is therefore based on a motor vehicle headlight that comprises one or more light modules, of which at least one light module is movable both vertically and horizontally. The movement of the light module can occur to implement a basic setting of the light module or the headlight before the headlight is used as intended. This occurs, for example, at a motor vehicle manufacturer at the end of the production line after the headlight has been installed in the vehicle, in a workshop after a repair or replacement of the headlight following a defect or accident, or at a technical testing organization as part of a roadworthiness check of the vehicle. Alternatively or additionally, the movement of the light module can also occur to implement a specific lighting function during the headlight's intended use, e.g.a horizontal movement to implement a dynamic cornering light function or a vertical movement to implement headlight range control or motorway light distribution with a raised horizontal cut-off line compared to conventional low beam.

[0003] To achieve a basic adjustment of a light module, it is known from the prior art to use a so-called "fixed point and two loose bearings system," which allows for basic adjustment in both the vertical and horizontal directions. The fixed point is located below or above the center of gravity of the light module, and the two loose bearings are each rotated 90° to the fixed point about an axis parallel to the light emission direction. For horizontal adjustment, the loose bearing is held vertically below or above the fixed point, creating a vertical axis of rotation around which the light module can be adjusted horizontally using the other loose bearing.Accordingly, for vertical adjustment, the floating bearing is held horizontally next to the fixed point, creating a horizontal axis of rotation around which the light module can be adjusted vertically using the other floating bearing. The floating bearings are preferably adjusted manually using a screw-type adjustment mechanism.

[0004] The horizontal and vertical adjustments are mechanically decoupled from each other. However, from a lighting technology perspective, they are a dependent system. As long as the rotation axes are in a plane perpendicular to the light emission direction, adjusting the light module around one of the rotation axes does not affect the position of the light module around the other rotation axis. However, as soon as one of the two rotation axes is no longer in the same plane and the light module is moved around the other rotation axis, this also affects the position of the light module around the rotation axis, which is not actually adjusted.

[0005] Mounting the light module at the center of gravity is important to best meet customer requirements, including those regarding resonance behavior. Since the center of gravity of the light module and thus also the rotation axes of conventional light modules are located relatively far away from the projection lens of the light module, the basic adjustment of the light module usually also results in significant lens movement. This is disadvantageous because fixed cover frames or bezels, which are provided inside the headlight housing to conceal the light module so that it cannot be seen through the cover plate from outside the headlight, require relatively large openings for the light module's lens so as not to restrict lens movement.In addition, large lens movements require a large light exit area in the area of the headlight cover to ensure that no light is blocked or shaded due to the lens movement, despite the different lens positions. This makes a narrow light exit area impossible to achieve with existing light modules.

[0006] US 2016 / 215951 A1 discloses a light module for a motor vehicle headlight with two separate optical modules, each producing a dimmed light distribution with a horizontal (flat and / or asymmetrical) cut-off line. The optical modules can be aligned vertically relative to one another so that at least partial sections of the cut-off lines are at the same height. To align the optical modules, they have mutually facing, curved sliding surfaces on which the optical modules slide relative to one another during alignment. The axis of rotation itself is defined by pins projecting laterally from one of the optical modules, which are mounted in corresponding bearings on the other optical module. Once the optical modules or the cut-off lines have been aligned, the optical modules are fixed in the aligned relative position to one another by means of securing means.The problem with the known light module is that the described mechanism can only be used to align or adjust the two optical modules relative to each other.

[0007] In addition, it has proven to be disadvantageous that the axis of rotation itself is defined by pins and corresponding bearings.

[0008] Furthermore, DE 10 2019 118 294 A1 discloses a light module for a motor vehicle headlight, which comprises a so-called light engine for generating light and a projection lens that projects the light in a field in front of the motor vehicle. The light engine is movable relative to the headlight housing, while the projection lens is stationary. The light engine is vertically adjustable relative to the projection lens about an axis of rotation running through the lens in order to adjust the headlight range. For this purpose, a radial bearing can be provided in the region of the lens. Alternatively, a curved guide with a curved path between the light engine of the light module and the headlight housing is proposed, wherein a center of curvature of the path lies on the axis of curvature. A disadvantage of the known light module is that the described mechanism can only be used for adjusting the headlight range.This document does not elaborate on the specific design of the curved path and the curved path. Furthermore, the problem underlying the present invention does not arise in this document, since the projection lens is stationary and only the light engine is moved.

[0009] Based on the described prior art, the present invention is based on the object of designing and developing a motor vehicle headlight of the type mentioned at the outset in such a way that the above-mentioned disadvantages are overcome and a particularly robust adjustment of the light module relative to the headlight housing can be realized.

[0010] To achieve this object, a motor vehicle headlight having the features of claim 1 is proposed. In particular, starting from the motor vehicle headlight of the type mentioned at the outset, it is proposed that a curved guide be provided between the first frame and the second frame, which curved guide is designed to enable a relative movement between the second frame and the first frame on a curved path about the second axis of rotation.

[0011] The second rotation axis is therefore a "fictitious rotation axis." The invention allows adjustment of the light module in both horizontal and vertical directions. At least the vertical adjustment is achieved with the aid of a curved guide.

[0012] The curved guide for vertical adjustment is provided between the first frame and the second frame. The curved guide is designed to enable relative movement between the two frames on a curved path. The curved path can define or predetermine the horizontal (second) axis of rotation of the light module. This has the advantage that the path can be bent such that it defines the axis of rotation as close as possible to one or more projection lenses of the light module, without the need for a bearing there. The path does not necessarily have to be uniformly curved. If the path is not uniformly curved, the second axis of rotation defined by it can move relative to the lenses of the light module during the movement of the light module, i.e. the axis of rotation is not in the same position and / or orientation throughout the entire movement of the light module.

[0013] However, according to a preferred embodiment of the invention, the curved path is a circular path. The axis of rotation associated with the circular path preferably runs through the center of the circular path. Particularly preferably, the curved path is formed as a cylindrical section, with the cylinder axis corresponding to the axis of rotation. The axis of rotation defined by the circular path remains in the same position and orientation during the movement of the light module relative to the lenses.

[0014] It would also be conceivable for the curved path to comprise several consecutive circular paths with the same or one or more different radii of curvature. However, the (fictitious) axes of rotation defined by the circular paths are preferably congruent. When the light module is pivoted around this axis of rotation, the lens, in an optimal case, does not move vertically, but rather tilts forward or backward in the direction of the light exit (around the axis of rotation).

[0015] According to an advantageous development of the invention, it is proposed that the light module has at least one projection lens, and that the first axis of rotation and / or the second axis of rotation extend at least in the vicinity of the at least one projection lens, preferably through the at least one projection lens, particularly preferably through a center of gravity of the at least one projection lens. This development has the advantage that the lens movement is minimal during the movement of the light module relative to the headlight housing. Accordingly, the openings in the cover panel or bezel can be made particularly small without restricting the movement of the light module.Likewise, a light exit opening and a cover plate of the headlight that closes it can be designed to be particularly flat, without blocking or shading the light passing through the lens of the light distribution by an edge of the headlight housing that delimits the light exit opening or other components.

[0016] In the following explanation, a Cartesian coordinate system is defined as follows: An x-axis corresponds to the direction in which the light emerges from the light module. For a light module directed straight ahead in a horizontal direction, this can correspond to the direction of travel of a motor vehicle into which the headlight is installed. A y-axis runs horizontally and perpendicular to the x-axis. A z-axis runs vertically and perpendicular to the x-axis and the y-axis. A horizontal adjustment of the light module thus corresponds to a movement in the xy-plane, while a vertical adjustment corresponds to a movement in the xz-plane.

[0017] The first axis of rotation of the light module preferably runs parallel to the z-axis. Alternatively, it can also be slightly inclined relative to the z-axis. The second axis of rotation of the light module roughly follows the course of the projection lenses, which in turn approximately follow the course or shape of the headlight or its cover plate. This means that the second axis of rotation does not necessarily have to run parallel to the y-axis. Likewise, the two axes of rotation do not have to run perpendicular to each other when looking into the headlight opposite to the light exit direction.

[0018] According to another preferred embodiment of the invention, it is proposed that the curved path is a circular path curved around the second axis of rotation, wherein, upon movement of the second frame relative to the first frame, the second frame or the first frame is supported on the circular path curved around the second axis of rotation in the radial direction with respect to the second axis of rotation. In particular, the circular path is designed as a cylinder section with a circular cross-section, wherein the inner or outer wall of the cylinder section forms a support surface for the first or second frame. If the cylinder section is formed on the first frame, an inner wall serves as a support surface for the second frame. If the cylinder section is formed on the second frame, an outer wall serves as a support surface for the first frame.

[0019] It is particularly preferred if the bearing on the circular path curved around the second axis of rotation is provided by means of rolling bearings. If the circular path curved around the second axis of rotation is formed on the first frame, the second frame has the rolling bearing(s) that roll on the circular path of the first frame. If the circular path curved around the second axis of rotation is formed on the second frame, the first frame has the rolling bearing(s) that roll on the circular path of the second frame.

[0020] It is conceivable that the rolling bearings are mounted in a floating manner on the first or second frame. When the frames move relative to each other, the rolling bearings also move relative to both the first frame and the second frame. The rolling bearings essentially roll on the two frames, thus enabling low-friction relative movement between the two frames.

[0021] Preferably, the circular path curved around the second rotational axis is formed on the second frame, and the rolling bearings are arranged on the first frame. In particular, the rolling bearings are arranged floating on the first frame.

[0022] Advantageously, the bearing on the circular path curved around the second axis of rotation is achieved by means of at least two rolling bearings spaced apart from one another in the circumferential direction of the circular path curved around the second axis of rotation. In particular, the two rolling bearings are arranged such that, in every position of the first frame relative to the second frame, the circular path remains in contact with the two rolling bearings during the relative movement of the frames to one another about the second axis of rotation. This ensures a defined and secure bearing of the circular path on the rolling bearings at all times, regardless of the current position of the frames relative to one another.

[0023] The running surface of the rolling elements can be flat or curved inwardly or outwardly in a plane in which the rolling element's axis of rotation extends. Accordingly, the running surface of the curved circular track or the inner or outer wall of the cylindrical section can be flat or curved outwardly or inwardly. The curvature of the running surfaces allows for the rolling bearings to be guided transversely to the rolling element's axes of rotation.

[0024] The rolling bearings are preferably designed as needle bearings. The rolling elements are designed as needles, which allows for a particularly low design.

[0025] Finally, it is proposed that several rolling bearings be combined to form a rolling bearing package, which can be fastened as a separate element to the first frame or the second frame. In particular, the rolling bearing package can be arranged floatingly on the first or second frame. The rolling bearing package can be manufactured in advance and arranged or fastened as a separate element to the corresponding frame. For the floating bearing, the rolling bearing package fastened to the first frame has two rolling bearings that face the running surface of the cam track formed on the second frame and roll thereon, and one rolling bearing that faces a running surface of the first frame and rolls thereon. Preferably, the first frame has two rolling bearing packages per cam track. Likewise preferably, the first frame has two cam tracks, both of which define the same second axis of rotation of the light module.

[0026] According to another advantageous development of the invention, it is proposed that a further curved guide is provided between the headlight housing and the first frame, which is designed to enable a relative movement between the first frame and the headlight housing on a further curved path. The further curved path is preferably a flat circular path running around the first axis of rotation. When the first frame moves relative to the headlight housing, the first frame or the headlight housing is mounted on the flat circular path running around the first axis of rotation in the axial direction with respect to the first axis of rotation. The bearing surface of the further curved path thus preferably has the shape of a side wall of a ring or of one or more ring sections. A central axis of the ring or of the ring sections or of the bearing surface corresponds to the first axis of rotation.

[0027] The first axis of rotation preferably extends vertically, parallel to the z-axis. Alternatively, the first axis of rotation can also extend at an angle to the z-axis, preferably inclined backward, with a lower section of the axis of rotation passing through the origin of a Cartesian coordinate system and an upper section of the axis of rotation being inclined backward in the negative x-direction, opposite to the light exit direction.

[0028] According to a preferred embodiment of the invention, a fixed point acts between the first frame and the headlight housing in the region of the first axis of rotation. The first axis of rotation runs through the fixed point. This forms a radial bearing and enables movement of the light module in the horizontal direction around the first axis of rotation.

[0029] Advantageously, the flat circular path extending around the first axis of rotation is formed on the headlight housing. The first frame preferably has two sliding surfaces spaced apart from one another in the circumferential direction of the circular path, resting on the circular path. During a movement of the light module around the first axis of rotation, the sliding surfaces slide over the circular path or the circular path sections. The circular path sections together form the circular path. They can be formed by ribs on the headlight housing.

[0030] According to a further preferred embodiment of the invention, it is proposed that at least one of the curved guide and the further curved guide be designed to enable both a basic setting of the light module before the intended use of the motor vehicle headlight and an adjustment of the light module during the intended use of the motor vehicle headlight. Advantageously, the curved guide is designed to realize both a basic setting of the light module and, during intended use, an adjustment of the light module in the vertical direction about a horizontal second axis of rotation. The further curved guide, on the other hand, is preferably designed to realize only a basic setting of the light module in the horizontal direction about the vertical first axis of rotation.

[0031] During basic adjustment, the zero position of the light distribution (e.g., when driving straight ahead and the vehicle is unladen) is set in accordance with legal requirements. During normal operation of the vehicle headlight, the light module can be adjusted to implement headlight range control, a specific lighting function (e.g., motorway light with a raised cutoff line for a dimmed light distribution), a dynamic cornering light function, or a partial high beam function (in a high beam distribution, areas in which other road users have been detected are shaded; the shaded areas are adjusted to the current position of the detected road users).

[0032] The basic setting of the light module is preferably achieved by a manually operable adjustment mechanism (e.g. worm gear or threaded rod with a carriage guided thereon for longitudinal displacement). The adjustment of the light module during intended use is preferably achieved electrically, in particular by motor (e.g. by means of a stepper motor) or magnetically (e.g. by means of a proportional electromagnet). As part of the basic setting about the second axis of rotation, the position of the electric motor or the electromagnet relative to the second frame can be changed manually. This changes the position and / or orientation of the second frame with the light module attached to it relative to the first frame in a zero position of the electric motor or the electromagnet. The changed position and / or orientation is referred to as the basic setting of the light module in the vertical direction.

[0033] Furthermore, it is conceivable for the light module to have multiple optical modules, wherein the light from at least two of the optical modules forms the predetermined light distribution, and the optical modules whose light forms the predetermined light distribution are adjustable relative to one another by means of a manually operable adjustment mechanism. The adjustment mechanism is designed to be independent of the curved guide and the curved path for adjusting the light module in the vertical and / or horizontal direction. The adjustment mechanism adjusts the relative position of the optical modules involved in generating the predetermined light distribution within the light module.

[0034] With the help of the adjustment mechanism, the position of the partial light distributions generated by the individual optical modules, in particular their light-dark boundaries, can be aligned with one another, in particular by bringing them to the same height. For example, one of the optical modules can generate a low-beam basic light (wide illumination with a flat horizontal light-dark boundary) and another of the optical modules can generate a low-beam spot (narrower illumination in the center with an asymmetrical horizontal light-dark boundary). The light-dark boundaries of the two partial light distributions are aligned with one another, preferably so that the flat horizontal sections of the light-dark boundaries are at the same height. This process can also be referred to as the basic setting of the light module or as the adjustment of the optical modules of the light module relative to one another.

[0035] Similarly, a basic adjustment can be made using the manually operated adjustment mechanism in a light module with only one optical module. The alignment of the optical module relative to the second frame of the light module can be adjusted or set.

[0036] The present invention makes it possible to enable vertical and horizontal movement of the light module without the need for bearings in the area of the rotation axes on both sides of the light module. At least one of the rotation axes is defined exclusively by the curvature of the curved path of the corresponding curved guide.

[0037] Furthermore, the invention allows for particularly small lens movement during the movement of the light module. In particular, virtually no lens movement can be achieved in the y- and z-directions, and minimal lens movement can be achieved in the x-direction.

[0038] A light exit opening of the headlight housing is usually closed by a cover plate. The invention allows the height (in the z-direction) of the cover plate to be significantly reduced. Openings of cover panels or bezels around the light module and thus gaps between the light module or its projection lens(es) and the cover panels or bezels can be kept particularly small. Furthermore, additional lighting functions of other light modules can be brought particularly close to the projection lens of the light module without fear of mechanical collision during movement of the light module. Mechanical components for moving the light module are not required in typical styling areas, thus allowing greater stylistic freedom. Finally, the horizontal and vertical adjustment of the light module are also independent of each other in terms of lighting technology.This means that the horizontal adjustment of the light module has no influence on the vertical position of the light distribution. This applies even if the rotation axes are no longer in the same plane perpendicular to the direction of light exiting the light module. This is achieved by ensuring that the vertical rotation axis for the horizontal adjustment is oriented in the z-direction in any position of the light module. Only in the case where the horizontal rotation axis for the vertical adjustment is no longer parallel to the y-axis, but is inclined to it, is there a very slight lighting-related influence of the vertical adjustment on the horizontal position of the light distribution.

[0039] Further features and advantages of the present invention are explained in more detail below with reference to the figures. They show: Fig. 1 shows a motor vehicle headlight according to the invention in accordance with a preferred embodiment; Fig. 2 a light module according to the invention according to a preferred embodiment in a perspective view from the front for use in a headlight according to Fig. 1; Fig. 3 the light module Fig. 2 in a perspective view from behind; Fig. 4 a first frame of the light module Fig. 1 according to a preferred embodiment in a perspective view from the front; Fig. 5 the first frame Fig. 4 in a view from above; Fig. 6 the light module Fig. 2 in a perspective view from the front; Fig. 7a to 7c the light module Fig. 6 in a plan view during a movement of the light module in the horizontal direction; Fig. 8a to 8c the light module Fig. 6 in a side view during a movement of the light module in the vertical direction; Fig. 9 a needle bearing package for use in a light module according to the invention in a ready-to-assemble state; Fig. 10 the needle bearing package Fig. 9 in a first manufacturing step; Fig. 11 the needle bearing package from Fig. 10 in a subsequent second manufacturing step; Fig. 12 the needle bearing package Fig. 9 in an assembled state; Fig. 13 an alternative needle bearing for use in a light module according to the invention; Fig. 14 a rolling bearing for use in a light module according to the invention; Fig. 15 an alternative rolling bearing for use in a light module according to the invention; Fig. 16 a light module according to the invention according to a further preferred embodiment in a perspective view from the front for use in a headlight according to Fig. 1; Fig. 17 the light module Fig. 16 in a perspective view from behind; Fig. 18 the light module Fig. 16 in a side view; Fig. 19 a first frame of the light module Fig. 16; and Fig. 20 an alternative embodiment of the rolling bearing from Fig. 14 for use in a light module according to the invention.

[0040] In Fig. Figure 2 shows a schematic view of an example of a light module 10 according to the invention. The light module 10 is designed as a so-called projection module with a complex light source (not shown). The complex light source comprises a plurality of semiconductor light sources, e.g., LEDs, arranged next to and / or one above the other in a matrix-like manner. Of course, the light module 10 can also have any other light source. The projection module 10 comprises at least one module lens 12 or projection lens. In the example shown, the light module 10 has a plurality of projection lenses 12 arranged next to one another. In the figures, the projection lenses 12 conceal the complex light source arranged behind them. The complex light source emits light that is shaped and modified by the module lenses 12. In particular, module lenses 12 designed as projection lenses can image the light in the area in front of the motor vehicle to generate a predetermined light distribution.In the example shown, the light module 10 comprises two optical modules 14, each having a complex light source and a plurality of module lenses 12. The light module 10 can be a component of a headlight 101 of a motor vehicle in the form of a light module 105 and / or 106, as shown by way of example in FIG. Fig. 1 and is explained in more detail below.

[0041] The headlight for motor vehicles is in Fig. 1 is designated in its entirety by the reference numeral 101. The headlight 101 comprises a housing 102, which is preferably made of plastic. In a light exit direction 103, the headlight housing 102 has a light exit opening which is closed by a transparent cover plate 104. The cover plate 104 is made of colorless plastic or glass. The plate 104 can be designed as a so-called clear plate without optically effective profiles. Alternatively, the plate 104 can be provided at least in some regions with optically effective profiles (e.g. cylindrical lenses or prisms) which cause the light passing through to be scattered, preferably in a horizontal direction.

[0042] In the example shown, two light modules 105, 106 are arranged inside the headlight housing 102. The light modules 105, 106 are arranged fixedly or movable relative to the housing 102. A dynamic cornering light function can be realized by a relative movement of the light modules 105, 106 to the housing 102 in the horizontal direction. A movement of the light modules 105, 106 around a horizontal axis, i.e., in the vertical direction, can be used to adjust the headlight range. Of course, more or fewer than the two light modules 105, 106 shown can also be provided in the headlight housing 102. At least one of the light modules 105, 106 is designed as a projection module 10 according to the invention.

[0043] A control unit 107 can be arranged in a control unit housing 108 on the outside of the headlight housing 102. Of course, the control unit 107 can also be arranged at any other location on the lighting device 101. In particular, a separate control unit can be provided for each of the light modules 105, 106, wherein the control units can be an integral part of the light modules 105, 106. Of course, the control unit 107 can also be arranged remotely from the lighting device 101, for example in the engine compartment of the motor vehicle. The control unit 107 serves to control and / or regulate the light modules 105, 106 orof subcomponents of the light modules 105, 106, such as light sources of the light modules 105, 106 or actuators for horizontal and / or vertical adjustment of the light modules 105, 106 or diaphragm elements of the light modules, in particular actuators for varying the size of a diaphragm opening of the diaphragm elements.

[0044] The control of the light modules 105, 106 or the subcomponents by the control unit 107 is carried out via connecting lines 110, which are Fig. 1 are shown merely symbolically by a dashed line. The light modules 105, 106 can also be supplied with electrical energy via the lines 110. The lines 110 are led from the interior of the lighting device 101 through an opening in the headlight housing 102 into the control unit housing 108 and there connected to the circuit of the control unit 107. If control units are provided as an integral part of the light modules 105, 106, the lines 110 and the opening in the headlight housing 102 can be omitted. Finally, the control unit 107 can comprise a plug element 109 for connecting a connecting cable to a higher-level control unit (e.g. in the form of a so-called body controller unit) and / or a power source (e.g. in the form of the vehicle battery).

[0045] A Cartesian coordinate system is Fig. 2, to which reference is made in the following explanations. An x-axis corresponds to the light exit direction 103 of the light from the light module 10. If the light module 10 is directed straight ahead in the horizontal direction, this can correspond to the direction of travel of the motor vehicle in which the headlight 101 is installed. A y-axis runs horizontally and perpendicular to the x-axis. A z-axis runs vertically and perpendicular to the x-axis and the y-axis. A horizontal adjustment of the light module 10 thus corresponds to a movement in the xy-plane, a vertical adjustment to a movement in the xz-plane.

[0046] In the Fig. 2, 3, and 6 to 8 show a light module 10 with two optical modules 14. Of course, the light module 10 can also have just one optical module 14 or more than two optical modules 14. If there are multiple optical modules 14, these do not necessarily have to be arranged side by side, but could also be arranged one above the other or offset from one another. Furthermore, it is conceivable that the light exit surfaces of the module lenses 12 do not lie in a common plane, but are arranged offset from one another in the x-direction, for example, because they follow the profile of a cover plate 104 of the headlight 101.

[0047] The light module 10 serves to generate a predetermined light distribution in the light exit direction 103 of the headlight 101 in front of the motor vehicle. The light module 10 comprises a first frame (so-called base frame) 16, which is movable relative to the headlight housing 102 about a first (e.g., vertical) axis of rotation 18, and a second frame (so-called module frame) 20, which is movable relative to the first frame 16 about a second (e.g., horizontal) axis of rotation 22 and to which the light module 10 or the optics modules 14 are attached. The first axis of rotation 18 and the second axis of rotation 22 intersect each other or are arranged skewed relative to each other. This also includes the case where the two axes of rotation 18, 22 are offset from each other in the x-direction. For example, when looking at the light module 10, the rotation axes 18, 22 can run perpendicular to each other, opposite to the light exit direction 103.Alternatively, they can simply run diagonally (not at a right angle) to each other.

[0048] It is proposed that a curved guide 24 be provided between the first frame 16 and the second frame 20, which curved guide is designed to enable a relative movement between the second frame 20 and the first frame 16 on a curved path 26. In the example shown, the headlight 101 comprises two curved guides 24a, 24b arranged at a distance from one another and having corresponding curved paths 26a, 26b. The curved guides 24a, 24b are arranged on both sides of the first axis of rotation 18 or a vertical center plane encompassing the axis of rotation 18 (cf. Fig. 4). Alternatively, it would also be conceivable for the curved guides 24a, 24b or the curved tracks 26a, 26b to both be located on the same side of the vertical center plane.

[0049] The light module 10 has at least one projection lens 12. The first axis of rotation 18 and / or the second axis of rotation 22 extend at least in the vicinity of the at least one projection lens 12, preferably through the at least one projection lens 12, particularly preferably through a center of gravity of the at least one projection lens 12 (cf. Fig. 6). If the optical modules 14 or the light exit surfaces of the lenses 12 are arranged offset from one another, the second axis of rotation 22 is preferably placed through the module lenses 22 in such a way that a movement of the light module 10, in particular in the vertical direction, results in a minimal movement of the module lenses 12 or their light exit surfaces in the z-direction.

[0050] The at least one curved guide 24 comprises the curved track 26, which defines the second axis of rotation 22, as well as corresponding rolling elements 28 (cf. Fig. 3) that roll on the track 26. The rolling elements 28 can be arranged floatingly on the first frame 16 or the second frame 20. During a relative movement of the frames 16, 20 to one another, the rolling elements 28 roll on corresponding running surfaces of both frames 16, 20.

[0051] In the example shown, the light module 10 comprises the base frame 16 for the basic horizontal adjustment and the module frame 20 for the basic vertical adjustment and for implementing headlight range adjustment (HLR). The module frame 20 accommodates the light module 10 or the optical modules 14 and moves on the base frame 16. The base frame 16 moves on a first circular path 30 (see FIG. Fig. 4-6) about the first rotation axis 18 to adjust the light emitted by the light module 10 in the horizontal direction (basic setting). The module frame 20, together with the light module 10 or the optical modules 14, moves on a second circular path 32 (cf. Fig. 6) about the second axis of rotation 22 in order to adjust the emitted light in the vertical direction (basic setting) and to implement the headlight range adjustment during the intended operation of the headlight 101.

[0052] For the basic adjustment of the light module 10 in the horizontal direction, a further curved guide 44 is provided between the headlight housing 102 and the first frame 16 (cf. Fig. 5), which is designed to enable a relative movement between the first frame 16 and the headlight housing 102 on a further curved path, in particular the first circular path 30.

[0053] The further curved path 30 is a flat circular path running around the first axis of rotation 18 or comprises circular path sections 46. When the first frame 16 moves relative to the headlight housing 102, the first frame 16 is supported on the flat circular path running around the first axis of rotation 18 or the circular path sections 46 with respect to the first axis of rotation 18 in the axial direction (cf. Fig. 5). For support, the first frame 16 has slide elements 48 that slide on the circular path or circular path sections 46. The slide elements 48 have sliding surfaces facing the circular path or circular path sections 46. These can be coated with sliding-promoting or friction-reducing materials.

[0054] A fixed point 50 acts between the first frame 16 and the headlight housing 102 in the area of the first rotation axis 18. Together with the sliding surfaces of the slide elements 48, the fixed point 50 forms a three-point bearing. The first frame 16 rotates around the fixed point 50 on the two sliding surfaces. In the example shown, the adjustment mechanism 34 comprises a slide and an adjusting screw.

[0055] The basic adjustment of the light module 10 in the horizontal direction is carried out by means of a first manually operable mechanical adjustment mechanism 34 (cf. Fig. 3). This changes the position of the first frame 16 relative to the headlight housing 102 or a component firmly connected thereto. The basic adjustment of the light module 10 in the vertical direction is carried out by means of a second manually operable mechanical adjustment mechanism 36. This changes the position of the second frame 20 relative to the first frame 16 or a component firmly connected thereto, or alternatively relative to the headlight housing 102 or a component firmly connected thereto. The adjustment of the light module 10 in the vertical direction or of the second frame 20 on which the light module 10 is arranged, during the intended operation of the headlight 101, is carried out by means of an electrically operated actuator 38, for example in the form of an electric motor, in particular a stepper motor.The second adjustment mechanism 36 preferably adjusts the relationship of the actuator 38 (and thus also of the module frame 20) to the base frame 16 or alternatively to the headlight housing 102.

[0056] The external interfaces for actuating the manually operable mechanical adjustment mechanisms 34, 36 for the horizontal and vertical basic settings have a fixed position on the headlight housing 102. When the light module 10 is manually adjusted, particularly in the horizontal direction, a relatively large relative movement occurs between the interface and the headlight housing 102. This can be compensated for by flexible / elastic components. To compensate for a horizontal adjustment, these flexible / elastic components preferably have a defined position in the direction in which the adjustment is made (here, the z-direction) and are flexible in the other two directions (here, the x- and y-directions).

[0057] A third manually operable mechanical adjustment mechanism 40 may be provided to adjust the relative position (i.e., position and alignment) of the optical modules 14 to one another. The adjustment mechanism 40 acts on one of the optical elements 14, while the other optical element 14 is fixedly attached to the second frame 20. The adjustment mechanism 40 changes the relationship of the movable optical element 14 to the second frame 20. The adjustment mechanism 40 comprises, for example, two adjustable loose bearings 40a, 40b and a fixed point 40c (concealed by the second frame 20 in Fig. 3). The two loose bearings 40a, 40b are arranged offset by approximately 90° relative to the fixed point 40c.

[0058] The manual adjustment mechanism 40 could also be used for light modules 10 with only one optics module 14 to adjust an orientation of the optics module 14 with respect to the second frame 20, if desired.

[0059] In the Fig. 7a-7c show an adjustment of the light module 10 around the vertical axis of rotation 18. Fig. 7a shows a zero position in which the light exit direction 103 essentially corresponds to the direction of travel of the motor vehicle when driving straight ahead. Fig. 7b, the light module 10 is adjusted so that the light exit direction 103 of the light module 10 is opposite to the Fig. 7a is directed a little further to the left. In Fig. 7c, the light module 10 is adjusted so that the light exit direction 103 of the light module 10 is opposite to the Fig. 7a is directed a little further to the right.

[0060] In the Fig. 8a-8c show a movement of the light module 10 around the horizontal rotation axis 22 by means of the actuator 38. The adjustment of the light module 10 for the basic setting by means of the adjustment mechanism 36 functions accordingly, only with smaller adjustment ranges. Fig. 8a shows a zero position in which the light exit direction 103 is essentially horizontal. Fig. 8b, the light module 10 is moved so that the light exit direction 103 of the light module 10 is opposite to the Fig. 8a is directed further upwards. In Fig. 8c, the light module 10 is moved so that the light exit direction 103 of the light module 10 is opposite to the Fig. 8a is directed further downwards.

[0061] In the present invention, the rotation axes 18, 22 are ideally centered relative to the module lenses 12. Since the rotation axes 18, 22 do not run through receiving interfaces for the storage of the frames 16, 20, as in conventional systems, but rather these storage interfaces are located far behind and below the optical modules 14, these rotation axes 18, 22 can also be referred to as “fictitious rotation axes”.

[0062] The receiving interfaces between the two frames 16, 20 can be realized, for example, by means of packages 42 of the roller bearings 28, in particular by means of rolling bearing packages, preferably by means of needle bearing packages (cf. Fig. 9-11). Fig. 9 shows a package 42 of the roller bearings 28 in a fully assembled state. Fig. 10 shows a first assembly step of the package 42, wherein it can be seen that the package 42 has two material layers 52, which are preferably made of a plastic material. The two layers 52 are folded together at a film hinge 54, with the roller bearings 28 being rotatably held between the two layers 52. The package 42 has further film hinges 56, at which the package 42 can be angled so that it is slipped over holding sections of the first frame 16 and is mounted thereon in a floating manner (see FIG. Fig. 12).

[0063] A center of gravity of the light module 10 is located in the x, y and z directions between these packages 42. However, the center of gravity is preferably offset in the x direction from the axis of rotation 22. For this reason, there is a constant tendency towards a circular movement of the module frame 20 relative to the base frame 16, which is prevented by the actuator 38 (e.g. the LWR motor). The equilibrium of these rotational forces would be achieved if the center of gravity were below the axis of rotation 22, i.e. if there were no offset in the x direction. The module frame 20 is mounted and moved on approximately ¼ of the entire circular path 26. Depending on the space conditions in the headlight housing 102, the module frame 20 can also be accommodated on a larger circular path 26. The greater the extent of support on the circular path 26, the better the force distribution.

[0064] The rotation axis 22 for vertical movement can be rotated by approximately 0° to 20° on the xy plane, depending on the arrangement of the optical modules 14, to achieve the smallest possible movement of the module lenses 12 in the z-direction when the light module 10 is adjusted or moved vertically. A slight inclination of the rotation axis 18 for horizontal movement would be possible, provided legal requirements for light distribution are met.

[0065] By means of the packages 42 of roller bearings 28, in particular by means of the rolling bearing packages, preferably by means of the needle bearing packages, a particularly low-wear movement of the frames 16, 20 relative to one another can be achieved. The packages 42 of roller bearings 28 are placed on the base frame 16. The packages 42 of roller bearings 28 are preferably arranged floatingly on the frame 16, so that when the frames 16, 20 move relative to one another, the roller bearings 28 roll on both the running surfaces of the first frame 16 and the running surfaces of the second frame 20. Thus, a relative rolling movement takes place between the base frame 16 and the module frame 20, thus preventing rubbing or grinding of the frames 16, 20 against one another. Instead of the roller bearings 28, plain bearings could also be used, which are shown, for example, in the Fig. 13-15 are shown.

[0066] In Fig. 13 is a steel needle bearing 58 with a silicone roller 60 and support on both sides in plain bearing bushings 62. The bushings 62, with the silicone roller 60 held on a bearing rod 64, are attached to the base frame 16 via a holding frame 66 using screws 68. A rolling contact or running surface to the module frame 20 is designated by the reference numeral 70. The bearing rod 64 is rotatably mounted at both ends in the bushings 62. The silicone roller 60 is arranged on the rod. The silicone material of the roller 60 can compensate for tolerances. Furthermore, it can transform a linear contact of the rolling contact 70 into a surface contact. It can dampen vibrations and eliminate impacts between two hard materials. Finally, it can also generate friction so that grinding takes place in a controlled manner between the bearing rod 64 and the bushings 62 and not on the frames 16, 20. This can reduce the risk of material abrasion, deposits and dust formation.The bearing rod 64 is preferably made of steel. The bushings 62 have a particularly good sliding material, e.g., Iglidur®, at least on their surfaces facing the bearing rod 64. However, the bushings 62 can also be made entirely of the particularly good sliding material. The roller 60 can be made entirely of silicone, or of another material and have a silicone coating only in the area of the rolling contact 70. Other damping materials, in particular elastomers, can also be used instead of silicone for the roller 60.

[0067] Fig. 14 shows an alternative bearing 72 comprising a roller 74 with a silicone coating 76. Instead of silicone, the coating 76 can also consist of any other damping material, in particular an elastomer. The roller 74 itself consists, for example, of steel or plastic. It is mounted on one side only in a plain bearing bush 78. The bush 78 has, at least on its surface facing the roller 74, a material with particularly good sliding properties, for example Iglidur®. However, the bush 78 can also consist entirely of the particularly good sliding material. The bearing bush 78 with the roller 74 rotatably mounted thereon is fastened to the base frame 16 by means of a screw 80. The rolling contact with the module frame 20 is again designated by the reference numeral 70. The silicone material of the coating 76 has the same advantages as the silicone material of the roller 60 in the example of the Fig. 13.

[0068] The risk of unintentional loosening of the screw 80 during normal operation, e.g., dynamic headlight range adjustment, can be prevented by applying a screw locking agent, e.g., in the form of adhesive or varnish to the screw 80. Alternatively or additionally, it would be conceivable, as in Fig. 20, the running surfaces between the roller 74 and the bushing 78 are slightly inclined and thus a small lateral force component running in the screw direction is generated, which always keeps the roller 74 pressed away from the screw 80.

[0069] This works particularly well if bearing 72 is designed according to the example of Fig. 20 are provided in pairs in the light module 10, with mirror-image bearings 72 preferably being provided to the right and left of the center of gravity of the base frame 16 (or a vertical center plane encompassing the center of gravity). This allows the forces that occur to balance each other out, and the module frame 20 or its curved guides 24 are held centrally between the bearings 72, similar to the wheels of a rail vehicle, where inclined running surfaces of the wheels keep the rail vehicle balanced on the rails and prevent a collar-shaped edge of the wheels from permanently coming into contact with the rails.

[0070] A light module 10, which supports 72 according to the Fig. 14 shown principle is used in the Fig. 16 to 18 shown. Fig. 19 shows only the first frame 16 of such a light module 10 and Fig. Figure 20 shows a preferred alternative embodiment of the bearing 72.

[0071] Based on the Fig. 16 to 18 it is clearly visible that the base frame 16 has two roller bearings 72 according to Fig. 14 or Fig. 20, between which a curved track 26a; 26b formed or arranged on the module frame 20 is guided. Two rolling bearings 72 each form a curved guide 24a; 24b together with one of the curved tracks 26a, 26b. The curved tracks 26a, 26b are preferably circular tracks. They do not necessarily have to have the same radius. However, it is advantageous if all curved tracks 26a, 26b define the same axis of rotation 22. In other words, the axes of rotation 22 defined by the curved tracks 26a, 26b should be identical.

[0072] In Fig. 15 shows a further example of a bearing 82, wherein a holding frame 84 is fastened to the base frame 16 by means of a screw 86. The holding frame 84 clamps a plain bearing bush 88 between the holding frame 84 and the base frame 16. A bearing shaft 90 is rotatably mounted in the bearing bush 88. Axial movement of the bearing bush 88 is prevented by corresponding receptacles or recesses in the base frame 16 and / or the holding frame 84, into which corresponding radial projections 92, e.g. in the form of a radially projecting collar, of the bearing bush 88 engage. On the other hand, the holding frame 84 holds the bearing shaft 90 in its axial position with the aid of a projection 94, which is part of the holding frame 84. The projection 94 engages in an annular groove formed in the bearing shaft 90.

[0073] A roller or roll 96 is rotatably mounted on the bearing shaft 90, laterally adjacent to the attachment of the bearing shaft 90 to the base frame 16. The roll 96 is prevented from sliding off the bearing shaft 90 in the axial direction by a radial widening 98 of the bearing shaft 90 at its distal end. The rolling contact with the module frame 20 is again designated by reference numeral 70.

[0074] The plain bearing bushing 88 has, at least on its surface facing the bearing shaft 90, a material with particularly good sliding properties, for example Iglidur®. However, the bushing 88 can also be made entirely of the particularly good sliding material. The bearing shaft 90 is preferably made of steel or plastic. The roller 96 can be made entirely of silicone, or of another material and have a silicone coating only in the area of the rolling contact 70. Other damping materials, in particular elastomers, can also be used instead of silicone for the roller 96. The silicone material of the roller 96 has the same advantages as the silicone material of the roller 60 in the example of the Fig. 13.

Claims

[1] Motor vehicle headlight (101) with a headlight housing (102) and a light module (10) movably arranged therein for generating a predetermined light distribution in a light exit direction (103) of the headlight (101), comprising a first frame (16) which is movable relative to the headlight housing (102) about a first axis of rotation (18), and a second frame (20) which is movable relative to the first frame (16) about a second axis of rotation (22) and to which the light module (10) is fastened, wherein the first axis of rotation (18) and the second axis of rotation (22) intersect one another or are arranged skewed relative to one another, characterized by that a curved guide (24) is provided between the first frame (16) and the second frame (20), which is designed to enable a relative movement between the second frame (20) and the first frame (16) on a curved path (26; 32) about the second axis of rotation (22). [2] Motor vehicle headlight (101) according to claim 1, wherein the light module (10) has at least one projection lens (12) and the first axis of rotation (18) and / or the second axis of rotation (22) extend at least in the vicinity of the at least one projection lens (12), preferably through the at least one projection lens (12), particularly preferably through a center of gravity of the at least one projection lens (12). [3] Motor vehicle headlight (101) according to claim 1 or 2, wherein the curved path (26) is a circular path (32). [4] Motor vehicle headlight (101) according to one of the preceding claims, wherein the curved path (26) is a circular path (26a, 26b) curved about the second axis of rotation (22), wherein upon movement of the second frame (20) relative to the first frame (16), the second frame (20) or the first frame (16) is mounted in the radial direction with respect to the second axis of rotation (22) on the circular path (26a, 26b) curved about the second axis of rotation (22). [5] Motor vehicle headlight (101) according to claim 4, wherein the mounting on the circular path (26a, 26b) curved around the second axis of rotation (22) is effected by means of rolling bearings (28; 72; 82). [6] Motor vehicle headlight (101) according to claim 5, wherein the mounting is effected by means of at least two rolling bearings (28; 72; 82) spaced apart from one another in the circumferential direction of the circular path (26a, 26b) curved around the second axis of rotation (22). [7] Motor vehicle headlight (101) according to claim 5 or 6, wherein the rolling bearings (28) are designed as needle bearings (58). [8] Motor vehicle headlight (101) according to one of claims 5 to 7, wherein the circular path (26a, 26b) curved around the second axis of rotation (22) is formed on the second frame (20) and the rolling bearings (28; 72; 82) are arranged on the first frame (16). [9] Motor vehicle headlight (101) according to one of claims 5 to 8, wherein the rolling bearings (28; 72; 82) arranged on one of the frames (16; 20) have a slightly inclined running surface (70) to the other frame (20; 16). [10] Motor vehicle headlight (101) according to claim 9, wherein roller bearings (28; 72; 82) formed as a mirror image of one another are arranged on one of the frames (16; 20) to the left and right of a vertical center plane comprising the center of gravity of the frame (16; 20) on which the roller bearings (28; 72; 82) are arranged. [11] Motor vehicle headlight (101) according to one of the preceding claims, wherein a further curved guide (44) is provided between the headlight housing (102) and the first frame (16), which is designed to enable a relative movement between the first frame (16) and the headlight housing (102) on a further curved path (46, 30). [12] Motor vehicle headlight (101) according to claim 11, wherein the further curved path (46, 30) is a flat circular path running around the first axis of rotation (18), wherein upon movement of the first frame (16) relative to the headlight housing (102), the first frame (16) or the headlight housing (102) is mounted on the flat circular path (46) running around the first axis of rotation (18) in the axial direction with respect to the first axis of rotation (18). [13] Motor vehicle headlight (101) according to claim 12, wherein a fixed point (50) acts between the first frame (16) and the headlight housing (102) in the region of the first axis of rotation (18). [14] Motor vehicle headlight (101) according to claim 12 or 13, wherein the flat circular path (46) extending around the first axis of rotation (18) is formed on the headlight housing (102) and the first frame (16) preferably has two sliding surfaces (48) resting on the circular path (46) at a distance from one another in the circumferential direction of the circular path (46). [15] Motor vehicle headlight (101) according to one of the preceding claims, wherein at least one (24) of the curved guide (24) and the further curved guide (44) is designed to enable both a basic setting of the light module (10) before the intended use of the motor vehicle headlight (101) and an adjustment of the light module (10) during the intended use of the motor vehicle headlight (101). [16] Motor vehicle headlight (101) according to one of the preceding claims, wherein the light module (10) has a plurality of optical modules (14), wherein the light from at least two of the optical modules (14) forms the predetermined light distribution and the optical modules (14) whose light forms the predetermined light distribution are adjustable relative to one another by means of a manually operable adjusting mechanism (40), wherein the adjusting mechanism (40) is designed independently of the curved guide (24) and the curved path (26). [17] Motor vehicle headlight (101) according to claim 16, wherein the adjustment mechanism (40) is designed to move at least one of the optical modules (14), the light of which forms the predetermined light distribution, relative to the second frame (20) and the other optical modules (14) attached thereto, the light of which forms the predetermined light distribution.

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