Preload element for a headlight alignment system

Abstract

A method and system include a housing, a vehicle lamp assembly supported by the housing, and a motor carriage supported for movement relative to the housing. An adjustment member is coupled to the motor carriage, and the motor carriage is movable by the adjustment member to adjust an orientation of the vehicle lamp assembly. A biasing member is responsive between the motor carriage and the housing to provide a preload.

Description

FIELD OF TECHNOLOGY

[0001] This disclosure generally relates to a method and system for headlamp alignment that utilizes a biasing member to stabilize headlamp components and maintain tolerances and clearances to prevent jamming and maintain alignment. GENERAL STATE OF THE ART

[0002] Vehicles contain many different types of lighting assemblies, such as headlights. These lights are adjusted during vehicle assembly to ensure that the lights' alignment is within a specified target range. Tolerance stackups and clearance issues can affect alignment stability and ability. SUMMARY

[0003] An assembly according to an exemplary aspect of the present disclosure includes, among other things: a housing; a vehicle lamp assembly supported by the housing; a snowmobile supported for movement relative to the housing; an adjustment member coupled to the snowmobile, the snowmobile being movable by the adjustment member to adjust an orientation of the vehicle lamp assembly; and a biasing member responsive between the snowmobile and the housing.

[0004] In a further non-limiting embodiment of the above assembly, the biasing member generates a preload force to bias the snowmobile away from the housing.

[0005] In a further non-limiting embodiment of any of the foregoing assemblies, the biasing member comprises a coil spring.

[0006] In a further non-limiting embodiment of any of the foregoing assemblies, the snowmobile includes a main body having a first arm extending outwardly from the main body to provide a first spring base, and wherein the housing includes a second arm extending outwardly from the housing toward the first arm to provide a second spring base.

[0007] In a further non-limiting embodiment of any of the foregoing assemblies, a first mounting tab is attached to the snowmobile and a second mounting tab is attached to the housing, and wherein the coil spring includes a first spring end attached to the first mounting tab and a second spring end attached to the second mounting tab.

[0008] In a further non-limiting embodiment of any of the foregoing assemblies, the biasing member comprises a flex arm.

[0009] In a further non-limiting embodiment of any of the foregoing assemblies, the flex arm extends from an end attached to the motor carriage to a distal end abutting the housing.

[0010] In a further non-limiting embodiment of any of the foregoing assemblies, the housing includes a guide channel that receives a portion of the motor carriage, and wherein the distal end directly abuts an open end surface of the guide channel.

[0011] In a further non-limiting embodiment of any of the foregoing assemblies, a mounting tab is attached to the housing, and the flex arm extends from an end attached to the mounting tab to a distal end abutting an end surface of the snowmobile.

[0012] In a further non-limiting embodiment of any of the foregoing assemblies, the adjustment element comprises a drive spindle coupled to the motor carriage associated with a motor.

[0013] In a further non-limiting embodiment of any of the foregoing assemblies, the motor carriage comprises a main body having a first arm extending outwardly from the main body to engage the drive spindle, a sliding portion extending along an edge of the main body to move within a guide channel formed within the housing, and a motor mounting portion coupled to the motor.

[0014] In a further non-limiting embodiment of any of the foregoing assemblies, the snowmobile includes a first interface and the housing includes a second interface, and wherein the biasing member extends from a first end associated with the first interface to a second end associated with the second interface.

[0015] In a further non-limiting embodiment of any of the foregoing assemblies, the biasing member comprises a spring.

[0016] In a further non-limiting embodiment of any of the foregoing assemblies, the biasing member comprises a flex arm.

[0017] A method according to an exemplary aspect of the present disclosure includes, among other things: supporting a vehicle lamp assembly with a housing; supporting a snowmobile for movement relative to the housing; coupling an adjustment member coupled to the snowmobile, wherein the snowmobile is movable by the adjustment member to adjust an orientation of the vehicle lamp assembly; and installing a biasing member to react between the snowmobile and the housing.

[0018] In a further non-limiting embodiment of the above method, the method includes generating a preload force with the biasing member to bias the snowmobile away from the housing.

[0019] In a further non-limiting embodiment of any of the foregoing methods, the method includes forming the motor carriage to include a main body having a first arm extending outwardly from the main body to engage the adjustment member, a sliding portion extending along an edge of the main body to move within a guide channel formed within the housing, and a motor mounting portion coupled to a motor.

[0020] In a further non-limiting embodiment of any of the foregoing methods, the method includes providing the snowmobile with a first interface and the housing with a second interface, and extending the biasing member from a first end associated with the first interface to a second end associated with the second interface.

[0021] In a further non-limiting embodiment of any of the foregoing methods, the biasing member comprises a spring.

[0022] In a further non-limiting embodiment of any of the foregoing methods, the biasing member comprises a flex arm.

[0023] The embodiments, examples, and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be considered independently of one another or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are inconsistent. SHORT DESCRIPTION OF THE CHARACTERS

[0024] The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the detailed description. The figures accompanying the detailed description may be briefly described as follows: Fig. 1 is a rear perspective view of a headlight assembly. Fig. 2 is an exploded view of an example of a prestressing element. Fig. 3 is a perspective view of the prestressing element of Fig. 2 in assembled state. Fig. 4A is a perspective view of the prestressing element of Fig. 2 in a first adjustment position. Fig. 4B is a perspective view of the prestressing element of Fig. 2 in a second adjustment position. Fig. 5 is a perspective view of another example of a prestressing member. Fig. 6A is a perspective view of another example of a biasing member. Fig. 6B is a side view of the prestressing element of Fig. 6A. Fig. 7 is a perspective view of the prestressing element of Fig. 6A as installed in an enclosure. Fig. 8 is a perspective view of another example of a prestressing member. DETAILED DESCRIPTION

[0025] This disclosure specifically describes a headlamp alignment method and system that utilizes a biasing element to stabilize headlamp components and maintain tolerances and clearances to prevent jamming and maintain alignment. These and other features are discussed in more detail in the following paragraphs of this detailed description.

[0026] Fig. 1 illustrates a vehicle 10 including a vehicle lamp assembly 12 that includes a lamp component 14 that is moved via an adjustment mechanism 16 to adjust an orientation of the vehicle lamp assembly 12. For example, the adjustment mechanism 16 can adjust the orientation upward 18 or downward 20. In this example, the vehicle lamp assembly 12 includes a headlamp assembly; however, the present system and alignment method could also be used with other types of lamp assemblies. In one example, the lamp assembly 12 includes an upper headlamp component 14a and a lower headlamp component 14b.

[0027] In one example, internal mechanisms of the light assembly 12 may include a horizontal motor 24 used to provide a pivoting movement, e.g., a right-to-left pivot, of the light assembly 12 when the vehicle corners. A vertical motor 26 may also be included to provide automatic leveling of the light assembly 12 during vehicle operation based on pitch. A bracket assembly 28 is used to mount the horizontal motor 24 and the vertical motor 26 to a vehicle structure.

[0028] In one example, a system for adjusting the light assembly 12 includes an adjustment device 30 coupled to an input drive rod 32 coupled to the adjustment mechanism 16, which may include, for example, an adjustment tool 34. In one example, the adjustment tool 34 includes an automated tool that provides a rotational drive input to the drive rod 32. Those skilled in the art, having the benefit of this description, will be able to determine the type of automated tool that would be employed for these purposes. In one example, the adjustment device 30 includes a 90-degree splined spindle adjustment device including a drive spindle 36. The drive spindle 36 is coupled to a movable motor carriage 38 associated with the vertical motor 26 and moving in translation, as indicated by an arrow 40.

[0029] The light assembly 12 also includes a connecting rod 42 that connects the upper light component 14a and the lower light component 14b. The connecting rod 42 is used to transmit movement of the lower light component 14b to the upper light component 14a. The connecting rod 42 moves in translation at opposite ends, as indicated by arrows 44, 46, and rotates about a fixed pivot point 48. Other fixed pivot points for the light assembly 12 include upper pivot points 50 and lower pivot points 52. The upper light component 14a can be rotated, as indicated at 54, and the lower light component 14b can be rotated, as indicated at 56.

[0030] As is well known, all vehicle headlights require an alignment system to align the headlights within a defined tolerance range, based on headlight specifications and performance requirements. This is achieved through the headlight's internal movement mechanisms. As discussed above, these mechanisms have many moving parts and can be complex. During alignment, these mechanisms have shifting tolerances and can flex, bind, and create stress in the system. As a result, external forces, such as hood slamming, road irregularities, vibration inputs, and thermal loads, can cause the initial preset alignment to change, for example, moving outside the defined, factory-set tolerance range.It is known that even very small movements of internal components of the lamp assembly associated with alignment can result in large changes in the overall alignment of the headlamp beam. For example, a 0.46 mm (0.02 inch) shift in the position of the motor carriage 38 results in a 25.4 mm (1 inch) alignment shift at 25 feet, which is a typical distance at which alignment requirements are adjusted. The present disclosure provides a system and alignment method that utilizes a biasing element to preload moving components within the headlamp assembly to maintain alignment stability and capability over time.

[0031] In one example, the vehicle lamp assembly 12 is supported in a housing 58 ( Fig. 3). The housing 58 may be used to support several different components of the vehicle lamp assembly 12. The housing 58 may be attached to a vehicle structure, such as a frame or body member (not shown).

[0032] In a Fig. 2, the motor carriage 38 includes a main body 60 with a first arm 62 extending outwardly from the main body 60 to engage the drive spindle 36. In one example, the main body 60 includes a ribbed structure. A sliding portion 64 extends along an edge of the main body 60 to move within a guide channel 66 formed within the housing 58. A motor mount portion 68 is coupled to the motor 26. In one example, the first arm 62 extends outwardly from one side of the main body 60, and the motor mount portion 68 extends outwardly from an opposite side of the main body 60. In one example, the sliding portion 64 extends along a top edge of the main body 60 and includes side edges received within the guide channel 66.

[0033] In one example, the guide channel 66 is open at one end 70 to receive the sliding portion 64. The sliding portion 64 translates along a linear path to adjust a position of the motor carriage 38 and the associated motor 26.

[0034] As in the Fig. 3 and 4A-4B, the arm 62 of the motor carriage 38 is coupled to the drive spindle 36, which rotates about a rotational axis. In one example, the arm 62 has a threaded interface connection to the drive spindle 36. In one example, the arm 62 moves the motor carriage 38 along a guide channel 66 during adjustment to the target alignment range. The input drive rod 32, coupled to the adjustment tool 34, is used to rotate the drive spindle 36 via the geared spindle adjustment device 30 to provide adjustment. During adjustment, the drive spindle 36 rotates about the rotational axis to drive the arm 62 along a linear translational path to adjust a position of the motor carriage 38 until a predefined nominal alignment target is reached.

[0035] Due to tolerance accumulation of the alignment system and external factors, such as hood slamming, uneven roads, cyclical temperature changes, etc., the alignment movement can be affected, leading to problems with alignment stability and capability. The present disclosure adds a preload to the system to shift any variation to other moving parts, e.g., shifting them to a smaller tolerance zone to stabilize them. The other moving parts can maintain the necessary tolerances and clearances to prevent binding.

[0036] Fig. Figure 2 shows an example of an assembly that provides the desired preload. In this example, a biasing element 72 reacts between the motor carriage 38 and the housing 58. The biasing element 72 generates a preload force to bias the motor carriage 38 away from the housing 58, ie, in Fig. 3 in a leftward direction. In one example, the biasing element 72 comprises a coil spring.

[0037] In this example, the main body 60 of the snowmobile 38 includes a second arm 74 extending outwardly from the main body 60. In one example, the second arm 74 is adjacent the sliding portion 64 and extends from an upper edge of the main body 60. In one example, the second arm 74 extends to a distal end 76 and provides a first spring base 78. The distal end 76 includes a reduced cross-section portion 80 surrounded by a first end 82 of the biasing member 72. One or more abutment surfaces 84 extend outwardly from the reduced cross-section portion 80 to provide the first spring base 78.

[0038] In this example, the housing 58 includes an arm 86 that extends outwardly from the housing 58 toward the second arm 74 to provide a second spring base 88. The arm 86 may comprise a separately attached part or may be integrally formed with the housing 58. A distal end 90 of the arm 86 includes a reduced cross-section portion surrounded by a second end 92 of the biasing member 72. One or more abutment surfaces 94 extend around the reduced cross-section portion of the distal end 90 to provide the second spring base 88.

[0039] By compressing the preload element 72, an additional preload is applied to the moving motor carriage 38, as at 98 in Fig. 3. The preload created by the preload element 72 closes any gap at tolerances in the spindle adjustment device and the thread associated with the drive spindle 36, as shown at 96. The preload also closes the gap at any tolerances in the carriage interface to the main housing 58, as shown at 100.

[0040] Fig. 4A is a perspective view of the biasing element 72 of Fig. 2 in a first adjustment position. When the drive spindle 36 is rotated, as indicated at 102, the motor carriage 38 moves back and forth (depending on the direction of rotation) within the guide channel 66 to align the headlight beam pattern. When the drive spindle 36 is rotated to move the motor carriage 38 to the left, as shown in Fig. 4B, the biasing element 72 is further compressed.

[0041] Fig. 5 shows another example of a biasing member 72 that includes a spring that provides a preload force between the housing 58 and the carriage 38. In this example, a first mounting tab 104 is attached to the motor carriage 38, and a second mounting tab 106 is attached to the housing 58. The biasing member 72 includes a coil spring 108 having a first spring end 110 attached to the first mounting tab 104 and a second spring end 112 attached to the second mounting tab 106. In one example, the mounting tabs 104, 106 may include metal plates with pins coupled to the spring ends 110, 112.

[0042] The Fig. 6A-6B show another example of a biasing member 72. In this example, the biasing member includes a flex arm 120 that provides the preload. The flex arm 120 applies spring tension when the arm flexes. The flex arm 120 extends from an end 122 attached to the motor carriage 38 to a distal end 124 abutting the housing 5, as shown in Fig. 7. In this example, one end 122 of the flex arm 120 extends outwardly from an upper edge of the main body 60 of the snowmobile 38 within the sliding portion 64. The main body 60 of the snowmobile 38 includes the first arm 62, the sliding portion 64, and the motor mount portion 68, as described above.

[0043] In one example, the flex arm 120 first extends upwardly from the top edge of the main body 60 and then includes a middle section 126 that curves downwardly back toward the top edge to the distal end 124 to form a C-shape. In one example, the flex arm 120 has a larger cross-section at one end 122 than at the middle section 126. In one example, the distal end 124 includes opposing extensions 128 that contact the housing 58 and form a T-shape.

[0044] In one example, the sliding portion 64 of the motor carriage 38 is received within the guide channel 66, and one end 122 of the flexarm 120 extends outwardly from a gap 130 formed between opposing rails 132 of the guide channel 66. The flexarm 120 curves back toward the open end 70 of the guide channel 66, and the extensions 128 of the distal end 124 directly abut an end surface 134 of the guide channel 66. When adjustments are made using the drive spindle 36, the flexarm 120 presses against the housing 58 and flexes with the movement of the motor carriage 38, thereby applying tension to the system, as in the previous spring configuration.

[0045] In one example, one end 122 of the flex arm 120 is integrally attached to the main body 60 of the motor carriage 38. The flex arm 120 could also be separately attached to the motor carriage 38. The geometry and thickness, e.g., the cross-section, of the flex arm 120 can be tuned based on tests specific to each light assembly 12 to apply a sufficient amount of preload to the alignment system without binding it or excessive tool forces.

[0046] Fig. Figure 8 shows another example of a preload member 72 that includes a flex arm 140 that provides a preload. In this example, a mounting tab 142 is attached to the housing 58, and the flex arm 140 extends from an end 144 attached to the mounting tab 142 to a distal end 146 that abuts an end surface 148 of the motor carriage 38.

[0047] The present disclosure provides an alignment system and method that reduces movement of mechanical parts inside headlights that would affect the alignment system after initial adjustments have been achieved. A biasing element provides a preload into the assembly. This increases headlight alignment capability and stability and can be easily customized for each lamp assembly. The increased headlight alignment stability and capability is achieved by reducing the ability of internal mechanisms to shift position due to actions such as hood slamming and electric motor actuation. This also allows the necessary moving parts and linkages to maintain their own tolerances to prevent jamming.A preload is additionally applied to moving parts and spindle adjustment devices to bias and hold parts in one direction, preventing them from shifting back and forth while still maintaining the ability to move. The use of a preload element also helps dampen vibrations and reduces the impact of temperature changes, high input loads, and vibrations on headlight alignment drift.

[0048] The foregoing description is exemplary and not restrictive in nature. Variations and modifications of the disclosed examples may occur to those skilled in the art without necessarily departing from the spirit of this disclosure. Accordingly, the scope of protection afforded by this disclosure can only be determined by reading the following claims.

[0049] According to the present invention, an assembly is provided comprising: a housing; a vehicle lamp assembly supported by the housing; a snowmobile supported for movement relative to the housing; an adjustment member coupled to the snowmobile, the snowmobile being movable by the adjustment member to adjust an orientation of the vehicle lamp assembly; and a biasing member responsive between the snowmobile and the housing.

[0050] According to one embodiment, the biasing element generates a preload force to bias the snowmobile away from the housing.

[0051] According to one embodiment, the biasing element comprises a spiral spring.

[0052] According to one embodiment, the snowmobile comprises a main body having a first arm extending outwardly from the main body to provide a first spring base, and wherein the housing includes a second arm extending outwardly from the housing toward the first arm to provide a second spring base.

[0053] According to one embodiment, the invention is further characterized by a first mounting tab attached to the snowmobile and a second mounting tab attached to the housing, and wherein the coil spring includes a first spring end attached to the first mounting tab and a second spring end attached to the second mounting tab.

[0054] According to one embodiment, the biasing element comprises a flexible arm.

[0055] According to one embodiment, the flex arm extends from an end attached to the snowmobile to a distal end adjacent to the housing.

[0056] According to one embodiment, the housing includes a guide channel that receives a portion of the snowmobile, and wherein the distal end directly abuts an open end surface of the guide channel.

[0057] According to one embodiment, the invention is further characterized by a mounting tab attached to the housing, and wherein the flex arm extends from an end attached to the mounting tab to a distal end abutting an end surface of the snowmobile.

[0058] According to one embodiment, the adjusting element comprises a drive spindle coupled to the motor carriage associated with a motor.

[0059] According to one embodiment, the motor carriage comprises a main body having a first arm extending outwardly from the main body to engage the drive spindle, a sliding portion extending along an edge of the main body to move within a guide channel formed within the housing, and a motor mounting portion coupled to the motor.

[0060] According to one embodiment, the snowmobile includes a first interface and the housing includes a second interface, and wherein the biasing member extends from a first end associated with the first interface to a second end associated with the second interface.

[0061] According to one embodiment, the biasing element comprises a spring.

[0062] According to one embodiment, the biasing element comprises a flexible arm.

[0063] According to the present invention, a method includes: supporting a vehicle lamp assembly having a housing; supporting a snowmobile for movement relative to the housing; coupling an adjustment member coupled to the snowmobile, the snowmobile being movable by the adjustment member to adjust an orientation of the vehicle lamp assembly; and installing a biasing member to react between the snowmobile and the housing.

[0064] In one aspect of the invention, the method includes generating a preload force with the biasing member to bias the snowmobile away from the housing.

[0065] In one aspect of the invention, the method includes forming the snowmobile to include a main body having a first arm extending outwardly from the main body to engage the adjustment member, a sliding portion extending along an edge of the main body to move within a guide channel formed within the housing, and a motor mounting portion coupled to a motor.

[0066] In one aspect of the invention, the method includes providing the snowmobile with a first interface and the housing with a second interface, and extending the biasing member from a first end associated with the first interface to a second end associated with the second interface.

[0067] In one aspect of the invention, the biasing element comprises a spring.

[0068] In one aspect of the invention, the biasing element comprises a flex arm.

Claims

[1] Assembly comprising: a housing; a vehicle lamp assembly supported by the housing; a snowmobile supported for movement relative to the housing; an adjustment member coupled to the snowmobile, the snowmobile being movable by the adjustment member to adjust an orientation of the vehicle lamp assembly; and a preload element that reacts between the snowmobile and the housing. [2] The assembly of claim 1, wherein the biasing member generates a preload force to bias the snowmobile away from the housing. [3] The assembly of claim 1, wherein the biasing member comprises a coil spring. [4] The assembly of claim 3, wherein the snowmobile includes a main body having a first arm extending outwardly from the main body to provide a first spring base, and wherein the housing includes a second arm extending outwardly from the housing toward the first arm to provide a second spring base. [5] The assembly of claim 3, including a first mounting tab attached to the snowmobile and a second mounting tab attached to the housing, and wherein the coil spring includes a first spring end attached to the first mounting tab and a second spring end attached to the second mounting tab. [6] The assembly of claim 1, wherein the biasing member comprises a flex arm. [7] The assembly of claim 6, wherein the flex arm extends from an end attached to the snowmobile to a distal end abutting the housing, and optionally wherein the housing includes a guide channel receiving a portion of the snowmobile, and wherein the distal end directly abuts an open end surface of the guide channel. [8] The assembly of claim 6, including a mounting tab secured to the housing, and wherein the flex arm extends from an end secured to the mounting tab to a distal end abutting an end surface of the snowmobile. [9] The assembly of claim 1, wherein the adjusting member comprises a drive spindle coupled to the motor carriage associated with a motor. [10] The assembly of claim 9, wherein the motor carriage comprises a main body having a first arm extending outwardly from the main body to engage the drive spindle, a sliding portion extending along an edge of the main body to move within a guide channel formed within the housing, and a motor mounting portion coupled to the motor. [11] The assembly of claim 10, wherein the snowmobile includes a first interface and the housing includes a second interface, and wherein the biasing member extends from a first end associated with the first interface to a second end associated with the second interface, and optionally wherein the biasing member comprises a spring or a flex arm. [12] Method comprising: Supporting a vehicle lamp assembly with a housing; supporting a snowmobile for movement relative to the housing; coupling an adjustment element coupled to the snowmobile, the snowmobile being movable by the adjustment element to adjust an orientation of the vehicle lamp assembly; and Installing a preload element to react between the snowmobile and the housing. [13] The method of claim 12, including generating a preload force with the biasing member to bias the snowmobile away from the housing. [14] The method of claim 12, including forming the motor carriage to include a main body having a first arm extending outwardly from the main body to engage the adjustment member, a sliding portion extending along an edge of the main body to move within a guide channel formed within the housing, and a motor mounting portion coupled to a motor. [15] The method of claim 14, including providing the snowmobile with a first interface and the housing with a second interface, and extending the biasing member from a first end associated with the first interface to a second end associated with the second interface, and optionally wherein the biasing member comprises a spring or a flex arm.

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