Cable Range Corrector Drive Unit with Intermediary Tensioning
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Solution Overview
Problem
Cable-operated range corrector control devices for motor vehicle headlamps face challenges in precision positioning due to play between threaded components, leading to differential tension and rotation issues, which affect beam correction accuracy and increase the overall size of the control device.
Innovation Solution
The control device design features a drive mechanism where the drive means is inserted into a connecting means with an internal thread, anchoring cables at a peripheral area surrounded by the thread, reducing the longitudinal size and minimizing play-related issues, allowing for closer cable positioning to the center and a reduced housing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If friction is introduced between the threaded axis and tapped surface to reduce play, then positioning precision is improved, but the rotation of the adjustment member becomes hard and usability deteriorates
Solution Approach 1:
A cable tensioning device is introduced as an intermediary mechanism between the adjustment member and the cables. This device includes a cable holder that can move along the threaded axis, allowing independent tension adjustment of each cable without requiring friction between the threaded axis and tapped surface. The intermediary mechanism eliminates the need for friction-based positioning while maintaining precise cable tension control.
Solution Approach 2:
The system is segmented into independent cable tensioning units, where each cable has its own adjustment mechanism on the cable holder. This segmentation allows each cable to be tensioned independently without affecting the other, eliminating the need for a centralized friction-based positioning system and improving both precision and ease of operation.
2Shape
If the threaded axis is positioned in the center of the driver, then structural symmetry is achieved, but cable positioning precision deteriorates due to increased play effect at the periphery
Solution Approach 1:
The cable holder is introduced as an additional dimensional element that can move along the threaded axis. This allows the cables to be positioned at optimal locations while the adjustment mechanism remains centralized. The problem is solved by adding a degree of freedom in the axial direction, separating the positioning function from the tensioning function.
Solution Approach 2:
The cable holder acts as an intermediary between the centralized threaded axis and the cables. It transfers the rotational movement of the adjustment member into axial movement, which then translates to cable tension adjustment. This intermediary allows precise cable positioning without requiring the threaded axis to be offset from the center.
3Ease of manufacture
If the driver longitudinal size is increased to accommodate both threaded axis and cable anchoring body, then cable anchoring is enabled, but the overall device size increases
Solution Approach 1:
The cable holder integrates multiple functions into a single component: it serves as the anchoring point for both cables, the interface for the adjustment member, and the mechanism for tension adjustment. By merging these functions into one compact component, the longitudinal size is minimized while maintaining all necessary capabilities.
Solution Approach 2:
The cable holder is designed as a multi-functional component that performs anchoring, adjustment, and tensioning functions. This universal design eliminates the need for separate bodies for each function, reducing the overall longitudinal size of the driver while maintaining ease of manufacture and cable anchoring capability.
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 configuration enhances precision in beam correction by minimizing rotational movement and reduces the overall size of the control device, improving user experience and reducing manufacturing costs.
Implementation Method 1
The driver is moved by a threaded shaft passing through it. At the end of the threaded shaft is fixed a control and adjustment device, generally a rotary control button located on the dashboard
Implementation Method 2
It is known, to face this drawback, to propose friction between the threaded axis and the tapped surface of the coach in order to reduce the play between these two surfaces
Data Source
Figure 1
Figure 2~3
AI summary
The device (7) has a drive unit (30) i.e. threaded cylindrical face domino, provided in a case (11) for translationally driving cables (8) into cylindrical sheaths (45) secured to the case. The cables are anchored in the drive unit. An adjustment unit i.e. rotative button (21), adjusts a position of the drive unit. A connection unit i.e. link (25), is engaged with the drive unit and arranged to transmit a movement of the adjustment unit. The drive unit is inserted into the connection unit that includes a tapped cylindrical skirt (27). The sheaths are fixed on an apron (50) secured to the case. USE : Control device for controlling a range corrector that is used for correcting range of beam of a headlight of a car. ADVANTAGE : The device avoids the link to cross the drive unit to bring the cables close to each other for allowing thickness of the sheaths to approach a central zone of the drive unit so as to achieve low variation of position due to a clearance between the drive unit and the link. The drive unit possesses reduced size by bringing the cables close to a center part of the drive unit so as to reduce size of the case in which the drive unit is inserted. DESCRIPTION OF DRAWINGS : The drawing shows an exploded perspective view of a control device of a leveler. 7 : Control device 8 : Cables 11 : Case 21 : Rotative button 25 : Link 27 : Tapped cylindrical skirt 30 : Drive unit 45 : Cylindrical sheaths 50 : Apron.