Angled Sliding Axis Connects Optical Module Support
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Solution Overview
Problem
The existing headlamp systems face challenges in maintaining the stability of the light beam cut-off within the 0.1% angular variation limit due to thermal expansion of plastic components, which affects the position of the reflector and subsequently the light beam height, especially during prolonged operation.
Innovation Solution
The proposed assembly features a connecting device with a sliding axis oriented at an angle between 5° and 45° relative to the vertical axis, allowing the adjustment means to move within the connecting device without influencing the beam orientation, and includes an intermediate piece with adjustable intermediate angles to optimize the orientation and prevent undesired displacements caused by expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the corrector and case are made of plastic to enable adjustment of beam height, then the ease of manufacture and adaptability are improved, but thermal expansion occurs during operation which causes unwanted movement of the reflector and changes beam height beyond the 0.1% angular variation limit
Solution Approach 1:
The connecting device is divided into a first portion and a second portion, with the first portion allowing longitudinal movement along the sliding axis while the second portion maintains the mechanical connection to the support. This segmentation enables the adjustment means to expand freely along the sliding axis without transmitting expansion forces to the support and reflector, thereby maintaining beam height stability while preserving the plastic material advantages.
Solution Approach 2:
The sliding axis is oriented at a specific angle of inclination between 5° and 45° relative to the vertical axis. This angular parameter is optimized to allow the adjustment means to move along the sliding axis during thermal expansion while preventing unwanted displacement of the support. The specific angle range represents a parameter change that resolves the contradiction between using plastic materials and maintaining beam stability.
2Reliability
If the adjustment means is allowed to move freely to accommodate thermal expansion, then the beam height stability is improved, but the complexity of the connecting device increases due to the sliding mechanism and angled axis design
Solution Approach 1:
The connecting device incorporates a sliding mechanism that transitions from a static rigid connection to a dynamic connection allowing longitudinal movement along the sliding axis. The first portion can move relative to the second portion, accommodating thermal expansion dynamically. This dynamic design resolves the contradiction by providing the necessary movement freedom while maintaining a relatively simple structural implementation through guided sliding along an angled axis.
3Reliability
If the sliding axis is oriented at an angle of 5° to 45° relative to the vertical axis, then the expansion movement is contained without affecting beam orientation, but the manufacturing precision requirements increase to ensure proper angular orientation
Solution Approach 1:
The connecting device acts as an intermediary element between the adjustment means and the support. It incorporates the sliding mechanism with the angled sliding axis that mediates the thermal expansion movement, allowing it to occur along the inclined axis while preventing transmission of displacement to the support. This intermediary function resolves the contradiction by absorbing the precision requirements into the connecting device itself rather than requiring high precision throughout the entire system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures that the light beam cut-off remains stable within the required angular variation limits, even under thermal expansion, by allowing the adjustment means to move without affecting the connecting device, thus maintaining consistent beam positioning and compliance with regulatory standards.
Implementation Method 1
since the corrector and the case which supports it are made of plastic, they expand and the corrector then transmits a movement to the support and therefore to the reflector
Data Source
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AI summary
The assembly (10) has a connecting device (12) connected between a support (11) of an optical module (7) and an adjusting unit (13). The adjusting unit adjusts the position of the support of the optical module. The connecting device comprises a portion (21) that allows displacement of the adjusting unit along a sliding axis (C), where the sliding axis is oriented at an angle of inclination (alpha) between 5 and 45 degree with respect to a vertical axis (V). The optical module projects a light beam along an optical axis (A). The sliding axis is located in a longitudinal plane. An independent claim is also included for a lighting and/or signaling device of a vehicle.