Vehicle headlamp

Abstract

A vehicle headlamp (1) comprises: a lamp unit (10); a leveling unit (30) that rotates the lamp unit (10) about a leveling axis (L2); and a hollow second spline shaft (S2) that extends along the leveling axis (L2) and on which torque from the leveling unit (30) acts. At least a part of a wiring (51) extending from the lamp unit (10) is inserted into the second spline shaft (S2).

Description

Vehicle headlights

[0001] The present disclosure relates to a vehicle headlamp.

[0002] Conventionally, a vehicle headlamp is provided with a connection cord for supplying power to a light source, a connection cord for supplying power to an actuator that rotates a lamp unit relative to a housing, etc. Patent Document 1 discloses a vehicle headlamp in which at least a portion of the connection cord is disposed inside a bracket to prevent damage or breakage of the connection cord.

[0003] Japanese Patent Application Publication No. 2014-146465

[0004] However, in the vehicle headlamp disclosed in Patent Document 1, the bracket rotates when aiming or leveling the vehicle headlamp, and the multiple connection cords arranged on the bracket may interfere with other components. If the connection cords interfere and are damaged or broken, the vehicle headlamp may malfunction.

[0005] An object of the present disclosure is to provide a vehicle headlamp in which wiring is less likely to interfere with other components.

[0006] A vehicle headlamp according to one aspect of the present disclosure comprises: a lamp unit; a leveling unit that rotates the lamp unit about a leveling axis; and a hollow shaft that extends along the leveling axis and on which torque from the leveling unit acts, wherein at least a portion of a first wiring extending from the lamp unit is inserted inside the shaft.

[0007] According to the present disclosure, it is possible to provide a vehicle headlamp in which wiring is less likely to interfere with other components.

[0008] 13 is a conceptual diagram of a vehicle headlamp according to an embodiment of the present disclosure. FIG. 14 is a perspective view of a lamp unit, a leveling unit, a swivel unit, and a lamp bracket. FIG. 15 is an exploded perspective view of a main unit. FIG. 16 is an exploded perspective view of a swivel unit. FIG. 17 is a diagram showing an attachment structure of a first bracket, a swivel unit, and a first spline shaft. FIG. 18 is a perspective view of a first spline shaft. FIG. 19 is a cross-sectional view of a first output gear and a first spline shaft in a cross section perpendicular to the swivel axis direction. FIG. 19 is a perspective view of a lamp unit and a leveling unit. FIG. 19 is a perspective view of a removal jig used when removing a first spline shaft. FIG. 19 is a diagram for explaining wiring in a lamp unit 10. FIG. 19 is a perspective view of a vehicle headlamp according to a second embodiment. FIG. 19 is a cross-sectional view of the left subunit shown in FIG. 12 taken along line XIII-XIII. FIG. 19 is a diagram for explaining wiring in a vehicle headlamp 1′ according to a second embodiment.

[0009] In the following description, front, rear, left, right, top and bottom are defined as directions seen by a passenger in a vehicle equipped with a vehicle headlamp. Unless otherwise specified, front, rear, left, right, top and bottom are defined when the vehicle headlamp is oriented to irradiate light in front of the vehicle. In addition, a front view refers to a view of the vehicle headlamp from the front.

[0010] <First embodiment> (Overall configuration) Fig. 1 is a conceptual diagram of a vehicle headlamp according to an embodiment of the present disclosure. As shown in Fig. 1, the vehicle headlamp 1 includes a housing 100 and an outer lens 200 made of a translucent material that forms a lamp chamber together with the housing 100. The vehicle headlamp 1 includes a lamp unit 10, a swivel unit 20, a leveling unit 30, and an extension Sa within the lamp chamber. In the following description, the combined unit of the lamp unit 10, the swivel unit 20, and the leveling unit 30 will be referred to as a main unit M.

[0011] The extension Sa is provided between the outer lens 200 and the main unit M, and is a component that prevents the components inside the lamp chamber and the inner surface of the housing 100 from being visible from the outside through the outer lens 200, thereby enhancing the aesthetic appearance of the vehicle headlamp 1.

[0012] The swivel unit 20 rotates the lamp unit 10 and the leveling unit 30 about a swivel axis L1 extending in the vertical direction relative to the housing 100.

[0013] The leveling unit 30 supports the lamp unit 10 so as to be rotatable about a leveling axis L2 extending in the left-right direction relative to the swivel unit 20.

[0014] The lamp unit 10 emits a high beam light distribution pattern and a low beam light distribution pattern. The lamp unit 10 includes a light source 17, optical components such as a reflector and a lens that project the light emitted from the light source 17 forward, and a lamp bracket 14 to which these components are attached (see FIG. 2 , which will be described later). While the illustrated example shows an example in which a single lens L is mounted, multiple lenses or multiple reflectors may be mounted. Furthermore, a single light source 17 or multiple light sources 17 may be provided.

[0015] In the vehicle headlamp 1 of the first embodiment, a single lamp unit 10 is rotatably attached to a housing 100 via a swivel unit 20 and a leveling unit 30 .

[0016] 2 is a perspective view of the lamp unit 10, the leveling unit 30, the swivel unit 20, and the lamp bracket 14. The lamp unit 10, the leveling unit 30, and the swivel unit 20 are connected to one another to form a single main unit M. The front surface of the housing 100 is provided with convex mounting portions 110 (110U, 110R, 110L) that protrude forward. In the illustrated example, three mounting portions 110U, 110R, and 110L are provided. The main unit M is attached to the housing 100 via these mounting portions 110U, 110R, and 110L.

[0017] (Main Unit M) Fig. 3 is an exploded perspective view of the main unit M. As shown in Fig. 3, the main unit M has a first bracket B1, a first spline shaft S1, a swivel unit 20, a second bracket B2, a second spline shaft S2, a leveling unit 30, and a lamp unit 10. For convenience of drawing, Fig. 3 shows the outline shapes of the first spline shaft S1 and the second spline shaft S2.

[0018] (First Bracket B1) The first bracket B1 is fixed to the housing 100. The first bracket B1 has three mounting portions 11 (11U, 11R, 11L). The mounting portions 11 are portions that extend in the front-rear direction or the left-right direction. The mounting portions 11 are provided with insertion holes 11H therein into which the mounting portions 110 of the housing 100 are inserted. By inserting the mounting portions 110 of the housing 100 into the mounting portions 11 of the first bracket B1, the first bracket B1 is fixed to the housing 100 so that it cannot be displaced.

[0019] In the illustrated example, the mounting portion 11 is composed of an upper mounting portion 11U, and left and right mounting portions 11L and 11R that are provided below the upper mounting portion 11U. In a front view of the lamp unit 10, the right mounting portion 11R is located to the right of the left mounting portion 11L. In the illustrated example, in a front view of the lamp unit 10, the upper mounting portion 11U, the left mounting portion 11L, and the right mounting portion 11R are located at the vertices of an equilateral triangle.

[0020] The upper mounting portion 11U and the left mounting portion 11L are connected by a left beam portion 12L. The upper mounting portion 11U and the right mounting portion 11R are connected by a right beam portion 12R. A plate-shaped bottom portion 13 extending in the front-rear and left-right directions is provided between the left mounting portion 11L and the right mounting portion 11R. This bottom portion 13 is provided with a through-hole 13H that penetrates in the up-down direction. Note that a lance structure can be used to fit the mounting portion 110 and the mounting portion 11. The lance structure positions the mounting portion 110 and the mounting portion 11 at predetermined positions relative to each other.

[0021] (First spline shaft S1) The first spline shaft S1 is fixed to the bottom 13 of the first bracket B1. The first spline shaft S1 is a hollow shaft portion extending along the swivel axis L1 that extends in the up-down direction. The first spline shaft S1 passes through a through-hole 13H in the bottom 13 of the first bracket B1 from below, and an upper portion of the first spline shaft S1 protrudes above the bottom 13 of the first bracket B1.

[0022] (Swivel unit 20) The swivel unit 20 rotates the lamp unit 10 about a swivel axis L1 extending in the vertical direction. The swivel unit 20 rotates the optical axis of the lamp unit 10 in the horizontal direction. A portion of the swivel unit 20 is attached to the first spline shaft S1 so as to be rotatable about the swivel axis L1. The swivel unit 20 engages with the first spline shaft S1 above the bottom 13 of the first bracket B1.

[0023] 4 is an exploded perspective view of the swivel unit 20. As shown in FIG. 4, the swivel unit 20 has a first casing 21 that includes a first motor MO, a first reduction gear unit D, and a first circuit board C.

[0024] The first casing 21 has a first case body 21A, a partition plate 21B, and a second case body 21C. The first case body 21A and the partition plate 21B form a circuit board accommodating chamber CR, and the second case body 21C and the partition plate 21B form a motor accommodating chamber MR.

[0025] The first circuit board C is accommodated in the board accommodation chamber CR. The first motor MO and the first reduction gear unit D are accommodated in the motor accommodation chamber MR. The output shaft of the first motor MO transmits torque to the first reduction gear unit D. The first reduction gear unit D is composed of a first gear T1, a second gear T2, a third gear T3, and a first output gear TO1. The first gear T1 meshes with the output shaft of the first motor MO and the second gear T2. The second gear T2 meshes with the first gear T1 and the third gear T3. The third gear T3 meshes with the second gear T2 and the first output gear TO1.

[0026] The first output gear TO1 is a cylindrical member extending along the swivel axis L1 (see FIG. 1 ). The first output gear TO1 has, on a portion of its outer circumferential surface, a tooth surface (first gear) TS that meshes with the third gear T3. The first gear T1, the second gear T2, and the third gear T3 are disposed at positions that overlap the outer circumferential surface of the first output gear TO1 in the direction of extension of the swivel axis L1.

[0027] The first output gear TO1 is fixed to the first spline shaft S1 shown in Figure 3 and meshes with the third gear T3. The rotation axes of the first gear T1, the second gear T2, the third gear T3, and the first output gear TO1 are all parallel to the swivel axis L1. The torque of the first motor MO is transmitted to the first output gear TO1 via the first gear T1, the second gear T2, and the third gear T3.

[0028] (Axial Fixation) Figure 5 is a diagram showing the attachment structure of the first bracket B1, swivel unit 20, and first spline shaft S1. Figure 5 shows a cross section along the swivel axis L1. The first output gear TO1 is provided inside the first casing 21 so as to be rotatable around the swivel axis L1 but not displaceable in the direction of the swivel axis L1.

[0029] 4, the first output gear TO1 is a hollow member into which the first spline shaft S1 can be inserted. A window W penetrating radially is provided in a portion of the outer circumferential surface of the first output gear TO1. Because the first output gear TO1 is a hollow member, it is possible to ensure the rigidity of the first output gear TO1 and to reduce its weight.

[0030] Fig. 6 is a perspective view of the first spline shaft S1. As shown in Fig. 6, the first spline shaft S1 has a flat, ring-shaped flange 22 extending in a direction perpendicular to the swivel axis L1, and legs 23 extending from the flange 22 along the swivel axis L1. A locking claw 23L is provided at the axial tip of the leg 23. The leg 23 is an elongated portion in the axial direction, and the tip is elastically deformable in the radial direction.

[0031] Returning to Figure 5, the first output gear TO1 and the through hole 13H provided in the bottom portion 13 of the first bracket B1 are positioned coaxially, and the first spline shaft S1 is passed through the through hole 13H of the first bracket B1 and inserted up to the first output gear TO1 so that the bottom portion 13 of the first bracket B1 is sandwiched between the swivel unit 20 and the flange portion 22 of the first spline shaft S1.

[0032] As the first spline shaft S1 is inserted into the first output gear TO1, the tips of the legs 23 in the insertion direction are pressed against the inner circumferential surface of the first output gear TO1 and elastically deform radially inward. When the first spline shaft S1 is further inserted into the first output gear TO1, the locking pawls 23L fit into the windows W of the first output gear TO1, as shown in Figure 5, and the elastic radially inward deformation of the legs 23 is released. With the locking pawls 23L fitted into the windows W in this manner, the locking pawls 23L come into contact with the windows W and the tips of the first insertion guide portions 25 abut against stepped portions formed on the inner surface of the first output gear TO1, preventing the first spline shaft S1 from moving in the direction of the swivel axis L1.

[0033] (Circumferential and Radial Fixation) As shown in FIG. 6 , the first spline shaft S1 has a plurality of first mounting tongues FT1 and a plurality of second mounting tongues FT2 that protrude from the flange portion 22 in the direction of the swivel axis L1. The plurality of first mounting tongues FT1 are provided at intervals in the circumferential direction. Each second mounting tongue FT2 is provided between the first mounting tongues FT1 in the circumferential direction. In this embodiment, three first mounting tongues FT1 and three second mounting tongues FT2 are formed in the circumferential direction, but the number of each of the first mounting tongues FT1 and the second mounting tongues FT2 is not limited to three.

[0034] Each first mounting tongue FT1 has a leg portion 23 with a locking claw 23L at its tip, a circumferential abutment portion 24, and a first insertion guide portion 25. A pair of circumferential abutment portions 24 are provided on both circumferential sides of the leg portion 23, sandwiching the leg portion 23. The circumferential abutment portions 24 extend from the flange portion 22 to a length greater than the length of the leg portion 23. The pair of circumferential abutment portions 24 extend at an angle such that the distance between them decreases with increasing distance from the flange portion 22. Ends of the circumferential abutment portions 24 opposite the flange portion 22 are connected in the circumferential direction by the first insertion guide portion 25. The locking claw 23L at the tip of the leg portion 23 is not connected to the first insertion guide portion 25. The outer peripheral surface of the first insertion guide portion 25 opposite the flange portion 22 has a conical shape whose outer diameter decreases with increasing distance from the flange portion 22. In the illustrated example, pairs of circumferential abutment portions 24 are provided at three locations spaced apart in the circumferential direction of the first spline shaft S1.

[0035] The second mounting tongue FT2 has a main body 26 that protrudes from the flange 22 in the direction of the swivel axis L1, and a second insertion guide 27 that is provided at the tip of the main body 26. Similar to the first insertion guide 25, the outer peripheral surface of the second insertion guide 27 has a conical shape whose outer diameter decreases with increasing distance from the flange 22.

[0036] 7 is a cross-sectional view of the first output gear TO1 and the first spline shaft S1 taken along a cross section perpendicular to the swivel axis L1. The first spline shaft S1 is positioned so that the locking pawls 23L engage with the window portions W of the first bracket B1. Because the locking pawls 23L contact the wall surfaces of the window portions W, the first spline shaft S1 and the first output gear TO1 are prevented from rotating relative to each other around the swivel axis L1.

[0037] 7, the through hole TOH of the first output gear TO1 does not have a circular cross section, and the first output gear TO1 has multiple protrusions P that protrude radially inward. The first mounting tongues FT1 of the first spline shaft S1 fit between the circumferential spaces between these protrusions P. Conversely, the protrusions P of the first output gear TO1 fit between the circumferential spaces between the multiple first mounting tongues FT1 of the first spline shaft S1, and the multiple main body portions 26 of the first spline shaft S1 are engaged with the multiple protrusions P of the first output gear TO1, respectively. The circumferential abutment portions 24 of the first spline shaft S1 abut against the side surfaces of the protrusions P. This prevents relative rotation between the first spline shaft S1 and the first output gear TO1 about the swivel axis L1.

[0038] 6, the pair of circumferential abutment portions 24 of the first spline shaft S1 are inclined so that the distance between them becomes narrower as they move away from the flange portion 22. As the first spline shaft S1 is inserted into the first output gear TO1, the force with which the circumferential abutment portions 24 are pressed against the protrusion P increases, preventing circumferential backlash from occurring between the first spline shaft S1 and the first output gear TO1.

[0039] 7 , when the first spline shaft S1 is not inserted into the first output gear TO1, the outer diameter of the second mounting tongue FT2 of the first spline shaft S1 and the outer diameters of the locking claws 23L, first insertion guide portions 25, and second insertion guide portions 27 of the first mounting tongue FT1 are slightly larger than the inner diameter of the insertion hole of the first output gear TO1. Therefore, when the first spline shaft S1 is inserted into the first output gear TO1, the first spline shaft S1 is elastically deformed radially inward. In this state, an elastic restoring force acts to displace the second mounting tongue FT2, the locking claws 23L of the first mounting tongue FT1, the first insertion guide portions 25, and the second insertion guide portions 27 radially outward. In other words, when the first spline shaft S1 is inserted into the first output gear TO1, an elastic restoring force acts on the first spline shaft S1, pushing the inner surface of the insertion hole of the output gear radially outward, preventing radial play from occurring between the first spline shaft S1 and the first output gear TO1.

[0040] With this structure, the first spline shaft S1 and the first output gear TO1 are fixed so that they cannot be displaced relative to each other. The first output gear TO1 is fixed to the first spline shaft S1, and the first spline shaft S1 is fixed to the housing 100 via the first bracket B1.

[0041] (Second Bracket B2) Returning to Figure 3, the second bracket B2 will be described. The second bracket B2 is fixed to the swivel unit 20. The second bracket B2 supports the leveling unit 30 so that it can rotate about the leveling axis L2. The second bracket B2 is located above the swivel unit 20. The second bracket B2 has a swivel fixing portion 28 that is fixed to the first casing 21 of the swivel unit 20, and a leveling support portion 29A to which the second spline shaft S2 is fixed.

[0042] In the illustrated example, the second bracket B2 is a plate-like member that is approximately U-shaped when viewed from the front. The second bracket B2 has a swivel fixing portion 28 located at the bottom of the U, a leveling support portion 29A, and an auxiliary support portion 29B. The leveling support portion 29A is provided on the left side of the swivel fixing portion 28. The auxiliary support portion 29B is provided on the right side of the swivel fixing portion 28. The swivel fixing portion 28 is a plate-like portion that extends in the front-rear and left-right directions. The leveling support portion 29A and the auxiliary support portion 29B are plate-like portions that extend in the front-rear and up-down directions.

[0043] The swivel fixing portion 28 of the second bracket B2 is provided with a fitting hole 28H that penetrates in the vertical direction. This fitting hole 28H fits into a fitting portion 20L provided on the upper surface of the first casing 21 of the swivel unit 20, thereby fixing the second bracket B2 and the swivel unit 20 together.

[0044] The leveling support portion 29A of the second bracket B2 is provided with a support hole 29H that penetrates in the left-right direction and extends along the leveling axis L2.

[0045] The second spline shaft S2 has the same structure as the first spline shaft S1. That is, the second spline shaft S2 fixes the positional relationship between the second bracket B2 and the leveling unit 30 in the same manner as the first spline shaft S1 fixes the positional relationship between the first bracket B1 and the swivel unit 20.

[0046] The leveling unit 30 has the same structure as the swivel unit 20. The motor of the swivel unit 20 differs from the motor of the leveling unit 30 only in output torque and size, and the components are the same. The reduction gear unit of the swivel unit 20 differs from the reduction gear unit of the leveling unit 30 in terms of gear size, number of teeth, number of gears, reduction ratio, etc., but they are common in that they are both configured with multiple gears.

[0047] In this way, by mounting the first reduction gear unit D on the leveling unit 30, the sliding resistance between the gears of the first reduction gear unit D is large, which prevents the lamp unit 10 from losing its vertical position due to vehicle vibrations and maintains the vertical position of the lamp unit 10. Furthermore, by sharing parts between the leveling unit 30 and the swivel unit 20, manufacturing costs can be reduced.

[0048] The connection structure between the second spline shaft S2, the leveling support portion 29A of the second bracket B2, and the leveling unit 30 is the same as the connection structure between the first spline shaft S1, the first bracket B1, and the swivel unit 20 described above, so detailed description thereof will be omitted.

[0049] (Fixing Structure of Lamp Unit 10 and Leveling Unit 30) Figure 8 is a perspective view showing the lamp unit 10 and the leveling unit 30. As shown in Figure 8, the lamp unit 10 includes a lamp bracket 14, a lens holder 15, a projection lens 16, and a light source 17. In the example shown, the lamp bracket 14 is made of metal and has fins that function as a heat sink in addition to supports that support the light source 17 and the lens holder 15. The lens holder 15 is attached to the front of the lamp bracket 14. This lens holder 15 supports the projection lens 16.

[0050] The lamp bracket 14 has a base portion 14A to which the lens holder 15 is attached, and a leveling support plate portion 14B, which is a plate-shaped member extending in the up-down and front-rear directions and provided on the side of the lamp bracket 14. The leveling support plate portion 14B has a fitting hole (insertion hole) 14D with a recess 14C formed in its inner peripheral surface. The second casing 31 of the leveling unit 30 has an insertion portion 31A that is inserted into the fitting hole 14D. The outer periphery of the insertion portion 31A is formed with a fitting portion (claw portion) 31B that can pass through the recess 14C. This fitting hole 14D is provided coaxially with the leveling axis L2.

[0051] With the insertion portion 31A inserted into the fitting hole 14D and the fitting portion 31B passing through the recess 14C, the lamp unit 10 is rotated relative to the leveling unit 30 along the circumferential direction of the insertion portion 31A, whereby the fitting portion 31B fits into the leveling support plate portion 14B. This fit between the fitting portion 31B and the leveling support plate portion 14B prevents the lamp unit 10 from moving along the leveling axis L2 relative to the leveling unit 30.

[0052] The leveling support plate 14B also has a boss 14F that protrudes toward the leveling unit 30. A screw hole (first screw hole) 14G is provided on the tip surface of the boss 14F. A screw mounting portion 31D with a screw hole (second screw hole) 31C is also provided on the second casing 31 of the leveling unit 30. The leveling unit 30 and the lamp unit 10 are fixed together by threading a screw that passes through the screw mounting portion 31D of the leveling unit 30 into the boss 14F of the leveling support plate 14B.

[0053] <Operation> When the swivel unit 20 is activated, the first motor MO generates torque that rotates the first output gear TO1 relative to the first casing 21. The first output gear TO1 is fixed to the first bracket B1 via the first spline shaft S1, and the first bracket B1 is also fixed to the housing 100. In other words, the first output gear TO1 is fixed to the housing 100. As a result, when torque is generated in the first output gear TO1, the first motor MO and the first casing 21 supporting the first motor MO rotate about the swivel axis L1 due to a reaction force. Because the lamp unit 10 is fixed to the first casing 21 via the second bracket B2 and the leveling unit 30, the lamp unit 10 also rotates together with the first casing 21 about the swivel axis L1. As described above, when the swivel unit 20 is activated, the lamp unit 10 rotates about the swivel axis L1, and the optical axis of the lamp unit 10 swivels about the swivel axis L1.

[0054] The operation of the leveling unit 30 is basically the same as that of the swivel unit 20. When the leveling unit 30 is operated, the motor of the leveling unit 30 generates torque that rotates the output gear relative to the second casing 31 of the leveling unit 30. The output gear of the leveling unit 30 is fixed to the second bracket B2 via the second spline shaft S2. The second bracket B2 is fixed to the swivel unit 20. In other words, the output gear of the leveling unit 30 is fixed to the swivel unit 20. As a result, when torque is generated in the output gear of the leveling unit 30, the motor of the leveling unit 30 and the second casing 31 supporting the motor are rotated around the leveling axis L2 by a reaction force. Because the lamp unit 10 is fixed to the second casing 31 of the leveling unit 30 via the lamp bracket 14, the lamp unit 10 also rotates together with the second casing 31 around the leveling axis L2. As described above, when the leveling unit 30 is activated, the lamp unit 10 rotates around the leveling axis L2, and the optical axis of the lamp unit 10 is leveled around the leveling axis L2.

[0055] <Others> According to the vehicle headlamp 1 of the present disclosure, when the main unit M is assembled in advance, the first bracket B1 can be attached to the housing 100 together with the main unit M. This significantly improves work efficiency compared to when the lamp unit 10, swivel unit 20, leveling unit 30, etc. are attached to the housing 100 individually.

[0056] Furthermore, when the lamp unit 10, swivel unit 20, leveling unit 30, etc. are individually attached to the housing 100, the respective attachment positions will differ depending on the type of vehicle headlamp 1. However, according to the vehicle headlamp 1 of the present disclosure, when the type of vehicle headlamp 1 is different, only the attachment structure of the first bracket B1 to the housing 100 needs to be different, and the structure of the main unit M including the lamp unit 10, swivel unit 20, and leveling unit 30 can be made common among different types of vehicle headlamp 1. Alternatively, when the type of vehicle headlamp 1 is different, even the attachment structure of the first bracket B1 to the housing 100 can be made common, making it easy to standardize components.

[0057] Furthermore, according to the vehicle headlamp 1 of the present disclosure, the swivel unit 20 and the leveling unit 30 use the first motor MO to change the optical axis of the lamp unit 10. Therefore, the optical axis of the lamp unit 10 can be moved more quickly than when an operator changes the optical axis of the lamp unit 10 by rotating a screw.

[0058] Furthermore, in conventional vehicle headlamps, unlike the vehicle headlamp 1 of the present disclosure, the optical axis of the vehicle headlamp is aligned using an aiming unit before shipping. However, with the vehicle headlamp 1 of the present disclosure, the aiming operation only requires setting the initial position of the first motor MO, so no aiming unit is required in addition to the swivel unit 20 and the leveling unit 30.

[0059] In the vehicle headlamp 1 of the present disclosure, a six-axis sensor (not shown) and a gyro sensor are mounted on the leveling unit 30. The leveling unit 30 is fixed to the lamp unit 10 and displaces together with the lamp unit 10. Therefore, the attitude of the lamp unit 10 can be directly detected by the six-axis sensor and the gyro sensor.

[0060] The six-axis sensor and gyro sensor may be mounted directly on the lamp unit 10, or may be mounted on the leveling unit 30 fixed to the lamp unit 10. If mounted on the leveling unit 30, they may be mounted on a circuit board. If the six-axis sensor and gyro sensor are mounted on a circuit board, the sensors can be easily fixed and powered on the circuit board.

[0061] 5, a removal guide portion 25R is provided on the inner peripheral surface of the leg portion 23. In the cross section shown in the figure, the removal guide portion 25R has a hook-like shape that protrudes radially inward from the inner peripheral surface of the leg portion 23 and is folded back toward the flange portion 22 at its tip. The inner peripheral surface of the hook-like barb at its tip is formed as an inclined surface whose diameter increases as it moves away from the flange portion 22 in the axial direction.

[0062] FIG. 9 is a perspective view of a removal jig SJ used when removing the first spline shaft S1 from the first output gear TO1. As shown in FIG. 9 , the removal jig SJ has a cylindrical base portion SJB and a cylindrical insertion portion SJI with a diameter smaller than that of the base portion SJB. The outer diameter of the insertion portion SJI is slightly smaller than the inner diameter of the inner peripheral surface of the first spline shaft S1. The tip of the insertion portion SJI of the removal jig SJ is provided with a plurality of removal tongue portions SJT spaced apart circumferentially and extending in the axial direction of the first spline shaft S1. The removal tongue portions SJT are arc-shaped portions when viewed axially. The inner diameter of the removal tongue portions SJT decreases in the clockwise direction. The clockwise tip of the removal tongue portion SJT is provided with a rotation stopper SJS that protrudes radially outward from the outer peripheral surface.

[0063] The procedure for removing the first spline shaft S1 from the swivel unit 20 and the first bracket B1 using the removal jig SJ will be described. First, the insertion portion SJI of the removal jig SJ is inserted into the first spline shaft S1, and the removal jig SJ is rotated counterclockwise until the leg portion 23 of the first spline shaft S1 abuts against the rotation stopper SJS. When the removal jig SJ is rotated counterclockwise, the inner peripheral surface of the removal tongue portion SJT comes into contact with the wall surface of the removal guide portion 25R of the first spline shaft S1. Because the inner diameter of the removal tongue portion SJT decreases in the clockwise direction, continuing to rotate the removal jig SJ clockwise pulls the removal guide portion 25R radially inward. When the removal guide portion 25R is pulled radially inward, the first mounting tongue FT1 of the first spline shaft S1 is displaced radially inward, and the locking pawl 23L disengages from the first output gear TO1. In this state, the removal jig can be pulled out together with the first spline shaft S1 from the swivel unit 20 and the first bracket B1.

[0064] (Wiring) Fig. 10 is a diagram for explaining the wiring in the lamp unit 10. As shown in Fig. 10, the lamp unit 10 is provided with wiring (first wiring) 51 for supplying power to the light source 17. The wiring 51 passes through the inside of the lamp bracket 14, is inserted through the inside of the second spline shaft S2, and is further inserted through the inside of the first spline shaft S1.

[0065] 6, the wiring 51 is inserted into the hollow second spline shaft S2 through the gaps between the second mounting tongues FT2 of the second spline shaft S2. The wiring 51 is then led out from the inside of the flange 22 of the second spline shaft S2 to the outside of the second spline shaft S2.

[0066] Furthermore, the wiring 51 is inserted into the hollow interior of the first spline shaft S1 through the gaps between the second mounting tongues FT2 on the first spline shaft S1, and then led out from the inside of the flange 22 of the first spline shaft S1 to the outside of the first spline shaft S1.

[0067] In this way, since the wiring 51 is inserted inside the second spline shaft S2 and the first spline shaft S1, even when the lamp unit 10 rotates around the leveling axis L2 and the swivel axis L1, the wiring 51 is unlikely to be displaced significantly and is unlikely to interfere with other components.

[0068] Furthermore, even when the swivel unit 20 is activated, the first spline shaft S1 does not displace, and therefore the wiring 51 passing through the interior of the first spline shaft S1 does not interfere with the first spline shaft S1. Similarly, even when the leveling unit 30 is activated, the second spline shaft S2 does not displace, and therefore the wiring 51 passing through the interior of the second spline shaft S2 does not interfere with the second spline shaft S2.

[0069] The lamp unit 10 is also provided with a wiring (second wiring) 52 for supplying power to a first motor (actuator) MO (see FIG. 4) in the leveling unit 30. The wiring 52 passes through the inside of the second spline shaft S2 and further passes through the inside of the first spline shaft S1.

[0070] More specifically, like the wire 51, the wire 52 is inserted into the hollow interior of the second spline shaft S2 through the gaps between the second mounting tongues FT2 of the second spline shaft S2 shown in Fig. 6. The wire 52 is then led out from the inside of the flange 22 of the second spline shaft S2 to the outside of the second spline shaft S2.

[0071] Furthermore, the wiring 52 is inserted into the hollow interior of the first spline shaft S1 through the gaps between the second mounting tongues FT2 on the first spline shaft S1, and then led out from the inside of the flange 22 of the first spline shaft S1 to the outside of the first spline shaft S1.

[0072] In this way, the wiring 52 extending from the first motor MO is also configured to pass through the inside of the second spline shaft S2 and the first spline shaft S1, just like the wiring 51, thereby preventing interference with other components and tangling of the wiring.

[0073] Specifically, when the leveling unit 30 is activated, the lamp unit 10 from which the wires 51, 52 are pulled out rotates about the leveling axis L2, causing the wires 51, 52 to be displaced as if twisted about the leveling axis L2. However, because the wires 51, 52 are inserted inside the second spline shaft extending along the leveling axis L2, the amount of displacement of the wires 51, 52 is small. For this reason, the wires 51, 52 are unlikely to interfere with other components and are prevented from becoming entangled with each other.

[0074] At least one of the first spline shaft S1 and the second spline shaft S2 may have a structure that does not include the second insertion guide portion 27 provided at the tip of the second mounting tongue portion FT2. In this case, the insertion work of the wires 51 and 52 into the first spline shaft S1 and the wires 51 and 52 into the second spline shaft S2 is easy.

[0075] 8 again, as described above, the second casing 31 of the leveling unit 30 and the lamp bracket 14 of the lamp unit 10 are fixed together. Furthermore, the second casing 31 and the second bracket B2 of the leveling unit 30 are slidably supported on the outer circumferential surface of the first output gear TO1 of the leveling unit 30. Furthermore, the first output gear TO1 is in contact with the outer circumferential surface of the second spline shaft S2.

[0076] Therefore, the lamp unit 10 is supported not only by the first reduction gear unit D provided in the leveling unit 30, but also by the second casing 31, first output gear TO1, first spline shaft S1, and second bracket B2 in the leveling unit 30. This reduces the load on the first reduction gear unit D, improving the durability of the first reduction gear unit D. Furthermore, the lamp unit 10 can be reliably supported by the second spline shaft S2 fixed to the second bracket B2, increasing the support rigidity of the lamp unit 10.

[0077] Furthermore, it is desirable that the outer diameter of the first output gear TO1 in the first reduction gear unit D and the outer diameter of the second spline shaft S2 inserted inside the first output gear TO1 be 10 mm or greater. In this way, when the outer diameters of the first output gear TO1 and the second spline shaft S2 are large, a wide contact area can be ensured between the second casing 31 and the first output gear TO1, and a wide contact area can be ensured between the first output gear TO1 and the second spline shaft S2. This reduces the surface pressure that each of the second casing 31, the first output gear TO1, and the second spline shaft S2 receives, thereby further improving the durability of the first reduction gear unit D, the first output gear TO1, and the second spline shaft S2.

[0078] As described above, the vehicle headlamp 1 of the present disclosure includes the lamp unit 10, the leveling unit 30 that rotates the lamp unit 10 about the leveling axis L2, and the hollow second spline shaft S2 that extends along the leveling axis L2 and on which torque from the leveling unit 30 acts. At least a portion of the wiring (first wiring) 51 extending from the lamp unit 10 is inserted into the second spline shaft S2. Because the wiring 51 is inserted into the second spline shaft S2 that is located at the rotation center between the lamp unit 10 and the leveling unit 30, even when the lamp unit 10 rotates about the leveling axis L2, the wiring 51 is unlikely to be displaced significantly and is unlikely to interfere with other components.

[0079] Furthermore, in the vehicle headlamp 1, the leveling unit 30 has a first motor (actuator) MO. In addition to the wiring 51, at least a portion of the wiring (second wiring) 52 extending from the first motor MO is inserted inside the second spline shaft S2. In this manner, the configuration in which the wiring 52 extending from the first motor MO is also inserted inside the second spline shaft S2 more reliably prevents the wirings from becoming entangled.

[0080] Furthermore, in the vehicle headlamp 1, the leveling unit 30 is in contact with the outer circumferential surface of the second spline shaft S2. In this manner, the leveling unit 30 and the second spline shaft S2 are in contact with each other, so that the length of the wiring 52 extending from the first motor MO of the leveling unit 30 can be shortened.

[0081] Furthermore, the inner diameter of the second spline shaft S2 is 10 mm or greater in the vehicle headlamp 1. By ensuring a sufficient inner diameter of the second spline shaft S2 in this manner, it is possible to ensure the strength of the second spline shaft S2 and to facilitate the work of wiring inside the second spline shaft S2.

[0082] Furthermore, in the vehicle headlamp 1, the second spline shaft S2 cannot be displaced relative to the second bracket B2 that supports the lamp unit 10. With this configuration, it is possible to more reliably prevent movement of the wiring 51 that passes through the inside of the second spline shaft S2.

[0083] Furthermore, in the above description, the second bracket B2 has been described as being U-shaped in front view, but the shape of the second bracket B2 is not limited to this. For example, the second bracket B2 may have a square frame shape in front view. That is, the second bracket B2 may have a shape in which an upper frame portion that connects the upper ends of the leveling support portions 29A and the auxiliary support portions 29B is added to the U-shaped second bracket B2 described above. This upper frame portion may have a support portion that is supported rotatably about the swivel axis L1 relative to the housing 100. This support portion and the first spline shaft S1 can support the second bracket B2 without wobbling about the swivel axis L1.

[0084] <Second embodiment> In the above-described first embodiment, a configuration has been described in which the first bracket B1 is fixed to the housing 100, the swivel unit 20 enables the second bracket B2, the leveling unit 30, and the lamp unit 10 to rotate about the swivel axis L1 relative to the first bracket B1, and the leveling unit 30 enables the lamp unit 10 to rotate about the leveling axis L2 relative to the second bracket B2. However, the present disclosure is not limited to this.

[0085] Fig. 11 is a perspective view of a vehicle headlamp 1' according to the second embodiment. As shown in Fig. 11, the vehicle headlamp 1' includes a third bracket B3 fixed to a housing (not shown), a leveling unit 30 that rotates relative to the third bracket B3 about a main leveling axis ML2, a fourth bracket B4 fixed to the leveling unit 30, and three subunits S (SM, SL, SR) that are supported rotatably relative to the fourth bracket B4 about swivel axes ML1, LL1, and RL1, respectively.

[0086] In the illustrated example, the subunits S include a left subunit SL located on the far left, a right subunit SR located on the far right, and a central subunit SM located between the left subunit SL and the right subunit SR.

[0087] The central subunit SM can rotate around the central swivel axis ML1 relative to the fourth bracket B4 by the swivel unit 20. The connection structure between the swivel unit 20 and the fourth bracket B4 is similar to the connection structure between the swivel unit 20 and the first bracket B1 in the first embodiment described above. Furthermore, the structure of the swivel unit 20 of this embodiment, including the motor and multiple gears, is similar to that of the swivel unit 20 of the first embodiment.

[0088] In this way, the central subunit SM is provided with a swivel unit 20 that rotates the lamp unit 10 of the central subunit SM about the central swivel axis ML1, but the left subunit SL and the right subunit SR are not provided with a swivel unit 20. The rotation of the swivel unit 20 of the central subunit SM is transmitted to the left subunit SL and the right subunit SR via a link unit LU provided on the fourth bracket B4.

[0089] The link unit LU has a central link bracket MLB provided on the central subunit SM, a left link bracket LLB provided on the left subunit SL, a right link bracket RLB provided on the right subunit SR, a left arm LA suspended between the central link bracket MLB and the left link bracket LLB, a right arm RA suspended between the central link bracket MLB and the right link bracket RLB, a left connecting part LC that rotatably connects the left arm LA and the left link bracket LLB, a right connecting part RC that rotatably connects the right arm RA and the right link bracket RLB, and a central connecting part MC that rotatably connects the left arm LA, the right arm RA, and the central link bracket MLB. When the central link bracket MLB rotates about the central swivel axis ML1, the displacement of the central link bracket MLB is transmitted to the left arm LA and the right arm RA, causing the left link bracket LLB and the right link bracket RLB to rotate about the left swivel axis LL1 and the right swivel axis RL1, respectively.

[0090] The link unit LU makes the amount of rotation of the center subunit SM about the center swivel axis, the amount of rotation of the left subunit SL about the left swivel axis, and the amount of rotation of the right subunit SR about the right swivel axis equal.

[0091] Figures 12 and 13 are schematic diagrams of the left subunit SL. Figure 12 is a side view of the left subunit SL, and Figure 13 is a cross-sectional view of the left subunit SL shown in Figure 12 taken along line XIII-XIII. As shown in Figures 12 and 13, the left subunit SL includes a left lamp unit 10L, a third spline shaft S3, a fixed cylinder portion FC, a left lamp bracket 14L to which the left lamp unit 10L is fixed, a left link bracket LLB, a left pre-aiming unit 30L, a left phase adjustment unit PU, and a left vibration suppression unit BU.

[0092] The third spline shaft S3 passes through the fourth bracket B4 and the left link bracket LLB and is fixed to the fixed cylinder portion FC. The window portion W of the output gear in the first embodiment is provided in the fixed cylinder portion FC of this embodiment, and the locking claw 23L of the third spline shaft S3 fits into the fixed cylinder portion FC. A left ramp bracket 14L and a left link bracket LLB are provided on the outer periphery of the fixed cylinder portion FC so as to be rotatable about the left swivel axis LL1. The left ramp bracket 14L and the left link bracket LLB slide along the outer periphery of the fixed cylinder portion FC.

[0093] The left pre-aiming unit 30L is provided on the left lamp bracket 14L. The left pre-aiming unit 30L supports the left lamp unit 10L relative to the left lamp bracket 14L so that the left lamp unit 10L can rotate about a left pre-aiming axis AA that is parallel to the main leveling axis ML2 (see FIG. 13). When the left pre-aiming unit 30L is activated, the left lamp unit 10L rotates about the left pre-aiming axis AA. The left pre-aiming unit 30L can adjust the vertical posture of the left lamp unit 10L more precisely than the leveling unit 30.

[0094] The left phase adjustment unit PU connects the left lamp bracket 14L and the left link bracket LLB. The left phase adjustment unit PU transmits the rotation of the left link bracket LLB about the left swivel axis LL1 to the left lamp bracket 14L. When the left link bracket LLB rotates about the left swivel axis LL1 via the link unit LU, the left lamp bracket 14L rotates about the left swivel axis LL1 via the left phase adjustment unit PU. The left phase adjustment unit PU can change the amount of advance angle between the left lamp unit 10L and the left link bracket LLB about the left swivel axis LL1. The advance angle is an amount (angle) that indicates how many degrees the left lamp unit 10L advances from a reference angle about the left swivel axis LL1 relative to the left link bracket LLB.

[0095] The left vibration suppression unit BU prevents rattle from occurring between the left link bracket LLB and the left lamp bracket 14L. The left vibration suppression unit BU continuously applies a force to the left lamp bracket 14L to rotate it in one direction about the left swivel axis LL1. This makes it less likely that a gap will occur between the left link bracket LLB and the left lamp bracket 14L, and reduces the likelihood of abnormal noise being generated when vibrations act on the vehicle headlamp 1'.

[0096] In this way, when the swivel unit 20 is activated, the central lamp unit 10M rotates around the central swivel axis ML1, the left lamp unit 10L rotates around the left swivel axis LL1 via the link unit LU, and the right lamp unit 10R rotates around the right swivel axis RL1 via the link unit LU.

[0097] Furthermore, when the leveling unit 30 is actuated, the third bracket B3 rotates about the leveling axis L2 relative to the housing 100. The third bracket B3 is provided with a central lamp unit 10M, a left lamp unit 10L, and a right lamp unit 10R. Therefore, when the leveling unit 30 is actuated, the central lamp unit 10M, the left lamp unit 10L, and the right lamp unit 10R rotate all at once.

[0098] The vehicle headlamp 1' according to the second embodiment described above also includes the lamp unit 10 in the right subunit SR, the leveling unit 30 fixed to the lamp unit 10, and a fourth bracket (bracket) B4 that rotatably supports the lamp unit 10 and the leveling unit 30. With this configuration, the angle at which the leveling unit 30 rotates matches the angle at which the lamp unit 10 rotates. Therefore, as with the first embodiment, the vehicle headlamp 1' according to the second embodiment is easy to design because it does not need to be designed differently for each vehicle model in order to adjust the optical axis of the lamp unit 10 in the up-down direction.

[0099] (Wiring) FIG. 14 is a diagram illustrating the wiring in the vehicle headlamp 1′ according to the second embodiment. As shown in FIG. 14 , three wires (first wires) 51A, 51B, and 51C are provided for supplying power to the light sources of the left subunit SL, the center subunit SM, and the right subunit SR, respectively. The wires 51A, 51B, and 51C are inserted through the hollow second spline shaft S2. Because the wires 51A, 51B, and 51C are inserted through the second spline shaft S2 in this manner, even when each lamp unit 10 rotates about the leveling axis L2, the wires 51A, 51B, and 51C are less likely to be displaced significantly and to interfere with other components.

[0100] Also provided is a wire 53 for supplying power to the first motor (actuator) MO (see FIG. 4) in the swivel unit 20. The wire 53 passes through the interior of the second spline shaft S2. In this manner, the wire 53 extending from the first motor MO also passes through the interior of the second spline shaft S2, similar to the wires 51A, 51B, and 51C, which more reliably prevents the wires from becoming tangled.

[0101] As described above, the present specification discloses the following:

[0102] (1) A vehicle headlamp comprising: a lamp unit; a leveling unit that rotates the lamp unit around a leveling axis; and a hollow shaft that extends along the leveling axis and on which torque from the leveling unit acts, wherein at least a portion of a first wiring extending from the lamp unit is inserted inside the shaft.

[0103] (2) The vehicle headlamp according to item (1), wherein the leveling unit has an actuator, and in addition to the first wiring, at least a portion of a second wiring extending from the actuator is inserted inside the shaft.

[0104] (3) The vehicle headlamp according to item (1) or (2), wherein the leveling unit is in contact with an outer circumferential surface of the shaft.

[0105] (4) The vehicle headlamp according to any one of items (1) to (3), wherein the inner diameter of the shaft is 10 mm or more.

[0106] (5) The vehicle headlamp according to any one of items (1) to (4), further comprising a bracket that supports the lamp unit, and the shaft is not displaceable relative to the bracket.

[0107] Although the embodiments of the present disclosure have been described above, it goes without saying that the technical scope of the present disclosure should not be interpreted as being limited by the description of the present embodiments. The present embodiments are merely examples, and it will be understood by those skilled in the art that various modifications of the embodiments are possible within the scope of the invention described in the claims. The technical scope of the present disclosure should be determined based on the scope of the invention described in the claims and its equivalents.

[0108] This application is based on Japanese Patent Application No. 2023-222316, filed on December 28, 2023, the contents of which are incorporated herein by reference.

Claims

1. A vehicle headlamp comprising a lamp unit, a leveling unit that rotates the lamp unit around a leveling axis, and a hollow shaft that extends along the leveling axis and on which torque from the leveling unit acts, wherein at least a part of a first wiring extending from the lamp unit is inserted into the shaft.

2. The vehicle headlamp according to claim 1, wherein the leveling unit has an actuator, and at least a part of a second wiring extending from the actuator is inserted into the shaft in addition to the first wiring.

3. The vehicle headlamp according to claim 2, wherein the leveling unit is in contact with an outer peripheral surface of the shaft.

4. The vehicle headlamp according to claim 1, wherein an inner diameter of the shaft is 10 mm or more.

5. The vehicle headlamp according to claim 1, further comprising a bracket that supports the lamp unit, wherein the shaft is non-displaceable with respect to the bracket.

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