Actuator

Abstract

To provide a new actuator configured so that a rod can be suppressed from rattling.SOLUTION: An actuator 42, which is used to change an irradiating direction of a vehicular lamp, comprises: a rotating member that rotates accompanying rotation of a motor; a rod 44, connected concentrically to the rotating member to be relatively rotatable, which has a connection part that is connected to a mechanism that tilts an optical member provided in the vehicular lamp; a housing 56 in which an opening part 56c through which the rod advances and retracts is formed; and a holding member 60, attached to the opening part 56c, which suppresses the rod from rattling in a direction crossing an advancing / retracting direction of the rod while holding the rod 44 slidably in the advancing / retracting direction. The rod is restricted by the holding member 60 from rotating when the rotating member rotates, so as to slide with respect to the holding member 60.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to an actuator. [Background technology]

[0002] Conventionally, a leveling actuator device that adjusts the optical axis of a vehicle headlamp according to the inclination angle of the vehicle to change the irradiation direction is known. For example, Patent Document 1 discloses an illumination corrector that includes an electric motor, a rod that rotates by the electric motor, and a mechatronics device that partially covers the periphery of the rod and converts the rotational motion of the rod into linear motion. A spherical part is provided at the tip of the rod, and the spherical part that is fitted into a connection part on the back of the reflector moves forward and backward to tilt the reflector, thereby changing the irradiation direction of the illuminator. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2009-26763 A Summary of the Invention [Problem to be solved by the invention]

[0004] The illumination corrector converts the rotational motion of the rod into a spiral motion by a mechatronic device disposed at least partially around the rod. As a result, the rod advances and retreats through an opening provided in the housing. However, in order for the rod to be moved by the mechatronic device, a certain amount of play is required between the rod and the mechatronic device. On the other hand, if there is play, the sliding rod may rattle relative to the mechatronic device.

[0005] In addition, the above-mentioned illumination corrector is configured such that the motor lies in the longitudinal direction of the housing and the rod moves forward and backward in a direction perpendicular to the longitudinal direction of the motor, so that further miniaturization is required in terms of the overall size of the illumination corrector.

[0006] The present invention has been made in view of the above circumstances, and one of its objects is to provide a new actuator that suppresses rattling of the rod, and another object is to provide a new configuration that realizes a compact actuator. [Means for solving the problem]

[0007] In order to solve the above problems, an actuator according to one embodiment of the present invention is an actuator used for changing the illumination direction of a vehicle lamp, and includes a rotating member that rotates with the rotation of a motor, a rod having a connection part that is connected to a mechanism that tilts an optical member provided in the vehicle lamp and is connected coaxially with the rotating member so as to be rotatable relative to the rotating member, a housing having an opening through which the rod advances and retreats, and a holding member that holds the rod slidably in the advance and retreat direction while suppressing rattling in a direction intersecting the advance and retreat direction of the rod and is attached to the opening. When the rotating member rotates, the rotation of the rod is restricted by the holding member, so that the rod slides relative to the holding member.

[0008] According to this aspect, the rod, which is coaxial with the rotating member, advances and retreats through the opening by sliding relative to the holding member as the rotating member rotates. Therefore, the rotating member and the rod can be integrated into a compact structure.

[0009] The rod may have a plurality of guide rails on its outer periphery in the axial direction, and the holding member may have a plurality of guide grooves on its inner periphery in the axial direction, and the guide rails may slide relative to the guide grooves, so that the rod can slide in the axial direction of the holding member without rotating.

[0010] The guide rails may be provided at equal intervals in the circumferential direction of the rod. As a result, each of the guide rails of the rod is guided at equal intervals by each of the guide grooves of the holding member. This makes it difficult for the rod to tilt relative to the holding member, and allows the rod to slide smoothly relative to the holding member.

[0011] The retaining member may have a protrusion formed on its outer periphery that engages with a snap fit provided on the inner periphery of the opening. The protrusion may be provided between the guide grooves. This allows the retaining member to be easily attached to the opening.

[0012] The rotating member may have a female screw formed in a hole along the rotating shaft, and the rod may have a male screw provided on the outer periphery of the end portion connected to the rotating member, and the male screw and the female screw may mesh to connect to the rotating member. This allows the rotating member and the rod to be rotatably connected to each other with a simple process.

[0013] The rod is connected to the rotating member so as to be movable between a first position where the rod abuts against the bottom of the hole in the rotating member when contracted and a second position where the rod abuts against a part of the holding member when extended, and the guide rail may overlap the female thread in the first position, whereby the guide rail overlaps the rotating member when the rod is contracted, allowing the rotating member and the rod to be shortened as a unit.

[0014] Another aspect of the present invention is also an actuator. This actuator is an actuator used for changing the irradiation direction of a vehicle lamp, and includes a flat motor, a rotating member that rotates with the rotation of the flat motor, a rod having a connection part connected to a mechanism that tilts an optical member included in the vehicle lamp and connected coaxially with the rotating member so as to be relatively rotatable, and a housing that accommodates the flat motor, the rotating member, and the rod. The rod is configured such that the connection part moves forward and backward relative to the rotating member with the rotation of the rotating member, and the rotation axis of the flat motor and the rotation axis of the rotating member are not parallel to each other.

[0015] According to this aspect, the rotation axis of the flat motor and the rotation axis of the rotating member are not parallel to each other, so that the thickness of the flat motor in the direction of the rotation axis is reduced, and the thickness of the housing in a predetermined direction can be reduced.

[0016] The housing may have an overall box-like shape and include a first member that supports the flat motor and a second member that covers an opening formed in the first member. The opening may be formed so that the flat motor is exposed when not covered by the second member. This allows the flat motor to be assembled to the first member through the opening of the first member that constitutes the housing.

[0017] If the height of the housing is H, the width is W, and the thickness is D (where H>W>D), the flat motor may be arranged so that the rotating shaft is along the thickness direction, and the rotating member is arranged along the width direction. This reduces the thickness of the flat motor in the direction of the rotating shaft, thereby making it possible to reduce the thickness of the housing.

[0018] The housing may have a slide hole formed in one of both widthwise faces, through which the rod slides.

[0019] The rotating member may have a gear on its outer periphery to which the rotation of the flat motor is transmitted, and a female screw formed in a hole along the rotating shaft, and the rod may have a male screw on its outer periphery, and the male screw and the female screw may mesh to connect to the rotating member. This allows the rotating member and the rod to be rotatably connected to each other with simple processing.

[0020] Any combination of the above components, and any conversion of the expression of the present invention between a manufacturing method, a device such as a lamp or lighting, a light-emitting module, a light source, etc. are also valid as aspects of the present invention. Effect of the Invention

[0021] According to one aspect of the present invention, rattling of the rod can be suppressed, and according to another aspect of the present invention, a compact actuator can be realized. [Brief description of the drawings]

[0022] [Figure 1] 1 is a cross-sectional view showing an example of a vehicle lamp including an actuator according to an embodiment of the present invention. [Diagram 2] 2 is a cross-sectional view of the vehicle lamp shown in FIG. 1, viewed from the front. [Diagram 3] 1 is an overall perspective view of an actuator according to an embodiment of the present invention; [Figure 4] FIG. 2 is an exploded perspective view of the actuator according to the present embodiment. [Diagram 5] 2 is a partial side view showing a main portion of a speed reducing mechanism in the actuator according to the present embodiment. FIG. [Figure 6] FIG. 2 is a perspective view of a rotating member according to the present embodiment. [Figure 7] FIG. 2 is a side view of the rotating member according to the embodiment. [Figure 8] FIG. 2 is a perspective view of a rod according to the present embodiment. [Figure 9] FIG. 9 is a view of the rod shown in FIG. 8 as seen from direction A. [Figure 10] FIG. 9 is a view of the rod shown in FIG. 8 as seen from direction B. [Figure 11] FIG. 9 is a view of the rod shown in FIG. 8 as seen from direction C. [Figure 12] FIG. 2 is a perspective view of a holding member according to the present embodiment. [Figure 13] 13 is a view of the rod shown in FIG. 12 as viewed from direction D. [Figure 14] FIG. 13 is a view of the rod shown in FIG. 12 as viewed from the E direction. [Figure 15] 13 is a view of the rod shown in FIG. 12 as viewed from the F direction. [Figure 16] 5 is a cross-sectional view of the actuator shown in FIG. [Figure 17] 17 is a diagram showing a state in which the rod is extended further than the state shown in FIG. 16. FIG. [Figure 18] 4 is a view showing a main part of the HH cross section of the actuator shown in FIG. [Figure 19] FIG. 11 is a cross-sectional view of an actuator according to a modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] The present invention will be described below based on preferred embodiments with reference to the drawings. The same or equivalent components, parts, and processes shown in each drawing are given the same reference numerals, and duplicated descriptions are omitted as appropriate. In addition, the embodiments are illustrative and do not limit the invention, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention.

[0024] (Vehicle lighting fixtures) Fig. 1 is a cross-sectional view showing an example of a vehicle lamp equipped with an actuator according to the present embodiment. Fig. 2 is a cross-sectional view of the vehicle lamp 10 shown in Fig. 1, seen from the front. The vehicle lamp 10 shown in Fig. 1 shows one of left and right headlights. The headlights are attached to both sides in the vehicle width direction at the front of the vehicle, and the pair of headlights illuminate the area ahead of the vehicle.

[0025] The vehicle lamp 10 includes a lamp housing 12 having an opening at the front, and a cover 14 that closes the opening of the lamp housing 12. The lamp housing 12 and the cover 14 form a lamp outer casing 16, and the interior of the lamp outer casing 16 is formed as a lamp chamber 16a.

[0026] A frame 18 is disposed in the lamp chamber 16a. The frame 18 has an upper support portion 18a provided at an upper end portion, a pair of lower support portions 18b, 18b provided at a lower end portion, and a unit mounting portion 18c provided at an intermediate portion. The pair of lower support portions 18b are disposed apart in the left-right direction of the vehicle.

[0027] A screw support member 20 is provided on the rear side of the lower support portion 18b of the frame 18. An upper front end portion of the screw support member 20 is provided as a spherical portion 20a. The screw support members 20, 20 are supported by the lamp housing 12 so as to be movable in the front-rear direction of the vehicle body.

[0028] Bearing members 22, 24, 24 are attached to the upper support portion 18a and the lower support portions 18b, 18b of the frame 18 in a state in which they penetrate therethrough, respectively.

[0029] The spherical portions 20a of the screw support member 20 are connected to the bearing members 24. The bearing members 24 are rotatable relative to the screw support member 20 in any direction.

[0030] A pair of aiming screws 26, 26 are supported in the lamp housing 12 in a state in which they can rotate freely but cannot move in the front-rear direction (axial direction). The aiming screws 26, 26 are arranged apart in the left-right direction of the vehicle, and their rear ends protrude rearward from the lamp housing 12. The aiming screw 26 has a threaded portion 26a, and the threaded portion 26a is coupled to the screw support member 20.

[0031] Lamp units 28, 28 are attached to the unit attachment portion 18c of the frame 18. The number of lamp units 28 attached to the unit attachment portion 18c may be one, or three or more.

[0032] The lighting unit 28 has a heat sink 30 that dissipates heat, a substrate 32 arranged on the heat sink 30, a light source 34 mounted on the substrate 32, a reflector 36 that reflects light emitted from the light source 34 forward, a projection lens 38 through which the light emitted from the light source 34 passes, and a holder 40 that holds the projection lens 38.

[0033] An actuator 42 is disposed in the lamp chamber 16a. The actuator 42 is disposed, for example, at the upper part of the lamp chamber 16a and on the rear side of the lamp unit 28, and is fixed to a part of the lamp housing 12.

[0034] (Beam axis adjustment in vehicle lighting fixtures) Next, we will explain the optical axis adjustment in the vehicle lamp 10. The vehicle lamp 10 is configured to allow aiming adjustment, which is an initial adjustment of the irradiation direction, and leveling adjustment, which adjusts the deviation of the optical axis that changes due to the weight of the vehicle load. The aiming adjustment includes left-right aiming adjustment and up-down aiming adjustment.

[0035] The left-right aiming adjustment is performed by rotating one of the aiming screws 26. When the aiming screw 26 is rotated, the screw support member 20 to which the threaded portion 26a is screwed is sent forward or backward depending on the rotation direction of the aiming screw 26, and the frame 18 and the lamp units 28, 28 are rotated integrally with each other, with the line connecting the spherical portion 20a of the other screw support member 20 and the spherical portion 46 at the tip of the rod 44 as the fulcrum axis. By rotating the frame 18 and the lamp units 28, 28 integrally, the direction of the optical axis of the lamp units 28, 28 is displaced left and right, and the left and right aiming adjustment is performed.

[0036] The vertical aiming adjustment is performed by rotating both aiming screws 26, 26 in the same direction. When the aiming screws 26, 26 are rotated, the screw support members 20, 20 to which the threaded portions 26a, 26a are screwed are sent forward or backward depending on the rotation direction of the aiming screws 26, 26, and the frame 18 and the lamp units 28, 28 are rotated integrally with the spherical portion 46 of the rod 44 as a fulcrum. By rotating the frame 18 and the lamp units 28, 28 integrally, the orientation of the optical axis of the lamp units 28, 28 is displaced up and down, and the vertical aiming adjustment is performed.

[0037] The leveling adjustment is performed by operating the drive mechanism of the actuator 42. When the drive mechanism is operated, the rod 44 moves in the front-rear direction of the vehicle relative to the lamp housing 12.

[0038] When the rod 44 is moved, for example, forward, the bearing members 22, 24, 24 are rotated relative to the spherical portion 46 and the spherical portions 20a, 20a, respectively, and the frame 18 and the lamp units 28, 28 are rotated together downward about the line connecting the spherical portions 20a, 20a as a fulcrum axis in accordance with the rotation of the bearing members 22, 24, 24. By the frame 18 and the lamp units 28, 28 rotating together, the orientation of the optical axis of the lamp units 28, 28 is displaced downward, and leveling adjustment is performed.

[0039] On the other hand, when the rod 44 is moved, for example, rearward, the bearing members 22, 24, 24 are rotated relative to the spherical portion 46 and the spherical portions 20a, 20a, respectively, and the frame 18 and the lamp units 28, 28 are rotated upward as a unit around the line connecting the spherical portions 20a, 20a as a fulcrum axis in accordance with the rotation of the bearing members 22, 24, 24. By the frame 18 and the lamp units 28, 28 rotating as a unit, the orientation of the optical axis of the lamp units 28, 28 is displaced upward, and leveling adjustment is performed.

[0040] (Actuator) Next, the configuration of the actuator 42 according to this embodiment will be described in detail. Fig. 3 is an overall perspective view of the actuator according to this embodiment. Fig. 4 is an exploded perspective view of the actuator according to this embodiment. Fig. 5 is a partial side view showing a main part of the reduction mechanism in the actuator according to this embodiment.

[0041] The actuator 42 is used to change the illumination direction of the vehicle lamp by the above-mentioned leveling adjustment. The actuator 42 includes a motor 48, a spur gear 52 that meshes with a pinion gear 48a fixed to the rotation shaft of the motor 48, a pin 54 that serves as the rotation shaft of the spur gear 52, a housing 56 having a bearing portion 56a that supports the pin 54 at its bottom, a cover 58 that covers one opening 56b of the housing 56, a holding member 60 that is attached to the other opening 56c of the housing 56, and a C-ring 62 that is attached to one end of the rod 44.

[0042] The actuator 42 further includes a control board 86 and a cover 88 that covers the other opening of the housing 56. The control board 86 is a printed wiring board, and is equipped with a connector 90 to which a cable that transmits a control signal from an external vehicle ECU or a headlamp vehicle ECU is connected, a capacitor 92, three Hall ICs 94 for detecting the rotational position of the rotor of the motor 48, and other elements. A control IC (not shown) that controls the positioning of the motor 48 is also mounted on the back side of the control board 86 shown in FIG. 4.

[0043] The motor 48 according to the present embodiment is a brushless DC motor, which is a type of flat motor, so that the thickness of the housing 56 is as thin as possible. Here, a flat motor refers to a motor in which the thickness CT of the case in the direction of the rotation axis is relatively thin compared to the diameter CD of the case that houses the main components, and is, for example, a motor that satisfies CD>CT. The spur gear 52 has a worm 64 fixed coaxially and meshes with a helical gear 66 provided on the outer periphery of the rotating member 50. The worm 64 and the helical gear 66 form a worm gear whose rotation axes are perpendicular to each other.

[0044] The rotating member 50 rotates in accordance with the rotation of the motor 48 via a reduction mechanism consisting of the pinion gear 48a, the spur gear 52, the worm 64, and the helical gear 66. In this way, by transmitting the rotation of the motor to the rotating member 50 via the reduction mechanism, even if a motor with high rotation speed and relatively small torque is used, the rotating member 50 can be rotated at a reduced rotation speed to an appropriate speed, thereby obtaining sufficient thrust. For this reason, a small and flat brushless DC motor can also be used for the actuator 42.

[0045] (Rotating parts) Fig. 6 is a perspective view of the rotating member according to this embodiment. Fig. 7 is a side view of the rotating member according to this embodiment. The rotating member 50 is a cylindrical member as a whole, and a female screw 68 is formed in a hole along the rotation axis at the front end where the rod 44 is connected. A groove 70 in which a C-ring 62 is attached is formed on the outer periphery of the rear end of the rotating member 50. The above-mentioned helical gear 66 is formed in the center of the rotating member 50. The rotating member 50 is made of a material mainly composed of nylon resin that does not contain glass fibers.

[0046] (rod) Fig. 8 is a perspective view of a rod according to this embodiment. Fig. 9 is a view of the rod shown in Fig. 8 from direction A. Fig. 10 is a view of the rod shown in Fig. 8 from direction B. Fig. 11 is a view of the rod shown in Fig. 8 from direction C.

[0047] The rod 44 has a spherical portion 46 at its front end. The spherical portion 46 is a connection portion that is connected to a bearing member 22 that constitutes part of a mechanism for tilting an optical member (lamp unit 28) that the vehicle lamp 10 includes. A male thread 72 that fits (meshes) with a female thread 68 of the rotating member 50 is formed on the outer periphery of the rear end of the rod 44. This allows the rod 44 to be connected to the rotating member 50 coaxially and rotatably relative to the rotating member 50. By forming threads on each of the rod 44 and the rotating member 50, the rotating member and the rod can be rotatably connected to each other by simple processing.

[0048] The rod 44 is provided with a plurality of guide rails 74 extending in the axial direction on its outer periphery. The rod 44 according to this embodiment is provided with three guide rails 74 at equal intervals (120° intervals) in the circumferential direction of the rod. An inclined portion 74a is formed at the front end of each guide rail 74. The rear end of each guide rail 74 is connected to an annular portion 76, and an annular space 78 is formed between the annular portion 76 and the male thread 72. As a result, when the rotating member 50 rotates relative to the rod 44 while being connected to the rod 44, the front end of the rotating member 50 passes through the space 78 while the male thread 72 and the female thread 68 are engaged with each other, and advances toward the spherical portion 46, or retreats away from the spherical portion 46.

[0049] The guide rails 74 are also connected near their centers by an annular portion 79. The position and diameter of an end face 79a of the annular portion 79 on the spherical portion 46 side are set so as to abut against an arc portion of a holding member 60, which will be described later. The rod 44 is made of a material different from that of the rotating member 50, and is mainly composed of nylon resin containing glass fiber. Note that instead of nylon resin, a resin with good sliding properties, such as polyacetal resin, may be used.

[0050] (Retaining member) Fig. 12 is a perspective view of a holding member according to this embodiment. Fig. 13 is a view of the rod shown in Fig. 12 as viewed from direction D. Fig. 14 is a view of the rod shown in Fig. 12 as viewed from direction E. Fig. 15 is a view of the rod shown in Fig. 12 as viewed from direction F.

[0051] The holding member 60 according to this embodiment is a member that holds the rod 44 slidably in the advancing and retracting direction while suppressing rattling in a direction intersecting the advancing and retracting direction of the rod 44, and is made of a material mainly composed of polyacetal resin. The holding member 60 is attached to an opening 56c of the housing 56 through which the rod 44 advances and retreats. The holding member 60 has a plurality of guide grooves 80 provided in the axial direction on its inner circumference. The holding member 60 according to this embodiment has three guide grooves 80 provided at equal intervals (120° intervals) in the circumferential direction of the holding member 60. The guide grooves 80 are configured so that the guide rails 74 of the rod 44 slide in them.

[0052] As a result, each of the multiple guide rails 74 of the rod 44 is guided at equal intervals by each of the multiple guide grooves 80 of the holding member 60. This makes it difficult for the rod 44 to tilt relative to the holding member 60, and the rod 44 slides smoothly in the axial direction of the holding member 60 without rotating. In addition, three arcuate portions 60b are provided at equal intervals so as to surround the opening 60a at the front end of the holding member 60, and are configured so that the annular portion 79 of the rod 44 abuts against them.

[0053] The holding member 60 has three equally spaced projections 82 formed on the outer periphery thereof, which engage with the square hole 56f provided on the inner periphery of the opening 56c shown in FIG. 4. The projections 82 are provided between the guide grooves 80. This allows the holding member 60 to be easily attached to the opening 56c, and the holding member 60 can hold the rod 44 without rotating or sliding in the opening 56c. Therefore, when the rotating member 50 rotates, the rotation of the rod 44 is restricted by the holding member 60. As a result, the rod 44, which is coaxial with the rotating member 50, advances and retreats from the opening 56c by sliding in the axial direction relative to the holding member 60 due to the rotation of the rotating member 50. In this way, the rotating member 50 and the rod 44 according to this embodiment can be integrated to form a compact advance and retreat mechanism.

[0054] FIG. 16 is a cross-sectional view of the actuator 42 shown in FIG. 3 along the line GG. FIG. 16 shows a state in which most of the rod 44 is contracted inside the housing 56. FIG. 17 shows a state in which the rod 44 is extended from the state shown in FIG. 16. The rod 44 is connected to the rotating member 50 so as to be movable between a first position P1 (the state shown in FIG. 16) where the rod 44 abuts against the bottom 50a of the hole of the rotating member 50 when contracted, and a second position P2 (the state shown in FIG. 17) where the rod 44 abuts against the arc portion 60b of the holding member 60 when extended. In the rod 44, the guide rail 74 overlaps with the female screw 68 at the first position P1. In other words, the guide rail 74 overlaps with the rotating member 50 when the rod 44 is contracted, so that the rotating member 50 and the rod 44 can be shortened as a unit.

[0055] The actuator 42 according to the present embodiment described above includes a motor 48 which is a flat motor, and a housing 56 which accommodates the motor 48, the rotating member 50, and the rod 44. The rod 44 is configured such that the spherical portion 46 advances and retreats relative to the rotating member 50 as the rotating member 50 rotates. As shown in FIG. 5, in the actuator 42, the rotation axis X1 of the motor 48 and the rotation axis X2 of the rotating member 50 are not parallel. In other words, the rotation axis X1 and the rotation axis X2 are in a twisted position. The angle between the rotation axis X1 and the rotation axis X2 according to the present embodiment is 90°.

[0056] Since the rotation axis X1 of the motor 48 and the rotation axis X2 of the rotating member 50 are in a twisted position, the thickness of the motor 48 in the rotation axis direction is reduced, and the thickness of the housing 56 in a predetermined direction can be reduced.

[0057] The housing (housing 56 and cover 58) of the actuator 42 has an overall box-like shape and includes the housing 56 that supports the motor 48, and the cover 58 that covers an opening 56b formed in the housing 56. As shown in Fig. 4, the opening 56b is formed so that the motor 48 is exposed when not covered by the cover 58. This allows the motor 48 to be assembled to the housing 56 through an opening 56c of the housing 56.

[0058] 3 has a height H, a width W, and a thickness D (where H>W>D), the motor 48 is disposed so that the rotation axis X1 is along the thickness direction, and the rotating member 50 is disposed so that it is along the width direction W. This reduces the thickness D of the motor 48 in the direction of the rotation axis X1, thereby making it possible to reduce the thickness of the housing 56. Also, the housing 56 has an opening 56c formed on one of both sides in the width direction as a slide hole through which the rod 44 slides.

[0059] (Actuator control method) Next, an example of a method for controlling the actuator will be described. An electronic control unit (hereinafter, referred to as a "vehicle ECU") that performs vehicle leveling control controls the operation of the actuator 42 based on the output from a sensor (e.g., a vehicle height sensor) provided on the vehicle side. Specifically, the vehicle ECU detects the vehicle inclination, calculates the inclination angle at that time based on the information from the sensor, and calculates control position information of the motor 48 required to realize the amount of movement (advancement and retreat) of the rod 44 in the actuator 42 so as to achieve the desired inclination angle (horizontal state). Then, the vehicle ECU outputs a signal corresponding to the calculated control position information to the control IC.

[0060] A signal corresponding to the control position information is input to the control IC via a connector 90. The motor 48 is electrically connected to a control board 86 and driven by the control IC. Three Hall ICs 94 are arranged on the control board 86 at predetermined intervals along the circumferential direction of the rotor of the motor 48. When the rotor magnet rotates together with the rotor, the magnetic field in each Hall IC changes, and the on / off state of each Hall IC changes, outputting a pulse signal corresponding to the rotation period of the rotor. The control IC counts the pulse signals and associates the count value with the rotation position of the motor 48.

[0061] (Actuator assembly method) Next, a method for assembling the above-mentioned actuator will be described. As shown in FIG. 4, the method for assembling the actuator according to this embodiment includes the steps of preparing a housing 56 having an opening 56b and an opening 56c on different sides, placing the rotating member 50 at a predetermined position on the housing 56 from the opening 56b, inserting a rod 44 connected to a mechanism for tilting an optical member provided in a vehicle lamp from the opening 56c and coaxially connecting it to the rotating member 50, and mounting a holding member 60 for holding the rod 44 in the opening 56c. The predetermined position for mounting the rotating member 50 is a position where a C-ring 62 mounted on the rear end of the rotating member 50 is held by a U-shaped protrusion 84 provided on the bottom of the housing 56. The C-ring 62 is a locking portion made of a material mainly composed of polyacetal resin.

[0062] According to this assembly method, the rotating member 50 and the rod 44 that are connected to each other can be inserted from different openings 56b, 56c and then connected coaxially, which increases the degree of freedom in the assembly process and makes assembly easier. Also, in some cases, the overall opening can be made smaller than if the parts were connected to each other in advance and then placed in the housing 56.

[0063] The assembly method according to this embodiment also includes the steps of mounting the motor 48 at a predetermined position in the housing 56 through the opening 56b, and mounting the spur gear 52 constituting a speed reduction mechanism that reduces the rotation of the motor 48 and transmits it to the rotating member 50 through the opening 56b at a predetermined position. This allows the rotation transmission mechanism including the motor 48, the speed reduction mechanism, and the rotating member 50 to be mounted through the opening 56b, so that the rotation transmission mechanism can be provided in the housing 56 without changing the orientation of the housing 56 or the orientation in which the members are mounted. Also, by attaching the holding member 60 to the opening 56c, the movement of the rod 44 can be restricted within a predetermined range.

[0064] In addition, the housing 56 has an opening 56b formed on one of both sides in the thickness direction, and an opening 56c formed on one of both sides in the width direction. With this, by placing the housing 56 with the other of both sides in the thickness direction as the bottom surface, it is possible to assemble members from both the openings 56b and 56c without rotating the housing 56.

[0065] (Assembly of the spherical part to the bearing component) In the actuator 42 according to this embodiment, the spherical portion 46 is finally assembled to the bearing member 22 shown in Fig. 1. At that time, as shown in Fig. 16, a large load L (several hundred N or more) is applied to the spherical portion 46 in the direction of the arrow, and the rear end portion 50b of the rotating member 50 tries to be displaced toward the inner wall 56d of the housing 56 via the rod 44.

[0066] However, the C-ring 62 is attached to the groove 70 near the rear end 50b, and the C-ring 62 as a locking portion fits into the groove of the protrusion 84, thereby locking the rear end 50b at a predetermined position in the housing 56. Therefore, when the rear end 50b tries to displace toward the inner wall 56d, a large force is applied to the C-ring 62, and if the amount of displacement is large, the C-ring 62 may deform or crack.

[0067] Therefore, the actuator 42 according to the present embodiment is provided with a displacement suppression portion that suppresses displacement of the rear end 50b between the rear end 50b of the rotating member 50 and the inner wall 56d of the housing 56. Fig. 18 is a view showing a main part of the HH cross section of the actuator 42 shown in Fig. 3.

[0068] The displacement suppression portion according to the present embodiment is a protrusion 56e provided on an inner wall 56d of the housing 56. Thereby, the protrusion 56e can be provided integrally with the housing 56 by devising a shape of the housing 56.

[0069] When there is no convex portion 56e, the rear end portion 50b shown in FIG. 18 can be displaced up to the distance d1 from the inner wall 56d. In that case, a large load may be applied to the C-ring 62 locked to the protrusion 84, causing it to deform or crack. However, by providing the convex portion 56e on the inner wall 56d, the gap between the rear end portion 50b and the convex portion 56e can be reduced to d2 (d2 < d1). As a result, the displacement amount of the rear end portion 50b is maximally reduced to the gap d2, and the load applied to the C-ring 62 is reduced. That is, by suppressing the displacement of the rear end portion 50b of the rotating member 50, the deformation and cracking of the C-ring 62 are suppressed.

[0070] The convex portion 56e according to the present embodiment is a rib extending in the direction of the thickness D. Thereby, the displacement of the rear end portion 50b of the rotating member 50 can be surely suppressed with a simple shape. Further, the gap d2 between the rear end portion 50b and the convex portion 56e may be 0.3 to 1.0 mm. Thereby, the displacement of the rear end portion 50b can be suppressed to 0.3 to 1.0 mm or less. Further, the height of the convex portion is 1.0 to 2.0 mm. Thereby, it is possible to provide the convex portion 56e that is less likely to interfere with other members in the housing 56.

[0071] (Modification example) In the above-described embodiment, the actuator 42 in which the rod 44 is provided with a male screw and the rotating member 50 is provided with a female screw has been described as an example. However, an actuator in which the rod is provided with a female screw and the rotating member is provided with a male screw may also be used. FIG. 19 is a cross-sectional view of an actuator according to a modification example. The same components as those of the actuator 42 are denoted by the same reference numerals, and the description thereof will be appropriately omitted. The main feature of the actuator 142 according to the modification example is that a rotating member 150 having a male screw 172 is connected to a rod 144 in which a female screw 168 is formed. The actuator 142 configured in this way has the same function as the above-described actuator 42.

[0072] Although the present invention has been described above with reference to the above-mentioned embodiment, the present invention is not limited to the above-mentioned embodiment, and suitable combinations or substitutions of the configurations of the embodiment are also included in the present invention. In addition, it is possible to suitably rearrange the combinations and processing order in the embodiment based on the knowledge of a person skilled in the art, and to make modifications such as various design changes to the embodiment, and the embodiment to which such modifications have been made is also included in the scope of the present invention. [Explanation of symbols]

[0073] 10 vehicle lamp, 28 lamp unit, 42 actuator, 44 rod, 46 spherical portion, 48 motor, 48a pinion gear, 50 rotating member, 50b rear end portion, 52 spur gear, 56 housing, 56b opening, 56c opening, 56d inner wall, 56e convex portion, 58 cover, 60 retaining member, 60a opening, 60b arc portion, 62 C-ring, 64 worm, 66 helical gear, 68 female thread, 72 male thread, 74 guide rail, 76 annular portion, 78 space, 79 annular portion, 79a end surface, 80 guide groove, 82 projection, 84 projection, P1 first position, P2 second position, X1 Rotation axis, X2 rotation axis, d1 spacing, d2 gap.

Claims

1. An actuator used to change the illumination direction of a vehicle lamp, A rotating member that rotates in accordance with the rotation of the motor; a rod having a connection portion connected to a mechanism for tilting an optical member included in a vehicle lamp, the rod being connected coaxially with the rotating member so as to be relatively rotatable; a housing having an opening through which the rod advances and retreats; a holding member that holds the rod slidably in a forward and backward direction while suppressing rattling in a direction intersecting the forward and backward direction of the rod and is attached to the opening, The actuator, characterized in that, when the rotating member rotates, the rotation is restricted by the holding member, and the rod slides relative to the holding member.

2. The rod has a plurality of guide rails provided on its outer periphery in the axial direction, The holding member has a plurality of guide grooves formed on an inner circumference thereof in the axial direction, The actuator according to claim 1 , wherein the guide rail slides along the guide groove.

3. 3. The actuator according to claim 2, wherein the plurality of guide rails are provided at equal intervals in a circumferential direction of the rod.

4. The retaining member has a protrusion formed on an outer periphery thereof that engages with a snap fit provided on an inner periphery of the opening, 4. The actuator according to claim 2, wherein the projection is provided between the guide grooves.

5. The rotating member has a hole along a rotation axis and a female screw formed in the hole, 5. The actuator according to claim 2, wherein the rod has a male thread on the outer periphery of the end portion connected to the rotating member, and the male thread engages with the female thread to connect to the rotating member.

6. The actuator of claim 5, wherein the rod is connected to the rotating member so as to be movable between a first position in which the rod abuts against a bottom of the hole of the rotating member when contracted and a second position in which the rod abuts against a portion of the retaining member when extended, and wherein in the first position, the guide rail overlaps with the female thread.

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