Headlamp Adjuster Mechanism with Retractable Holder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing headlamp adjustment mechanisms are inaccessible to end users due to tamper-proof devices, making it difficult for vehicle assembly plants to aim headlamps during production, leading to feasibility issues, additional labor, and potential recalls.
Innovation Solution
A headlamp adjuster mechanism that moves between an adjustment position and an inaccessible stowed position within the lamp housing, utilizing a holder and resilient member to secure the adjuster in place, allowing for temporary access with an aiming tool and then retracting for tamper-proofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tamper-proof device is placed over the horizontal adjuster to prevent end user access, then the headlamp position cannot be changed by users, but vehicle assembly plants cannot aim headlamps during production
Solution Approach 1:
The adjuster mechanism is segmented into two functional parts: a permanent housing that remains tamper-proof, and a temporary holder that provides access during assembly. The holder is a separate component that can be removed after aiming, leaving the adjuster enclosed and secure.
Solution Approach 2:
The holder is installed beforehand to enable headlamp aiming during assembly. After the aiming process is complete, the holder is removed, and the adjuster automatically retracts into the housing, providing tamper-proof protection for normal operation.
2Ease of operation
If the adjuster is made accessible for plant adjustment, then headlamp aiming is possible, but end users can also alter the position
Solution Approach 1:
The adjuster mechanism transitions from a static enclosed state to a dynamic accessible state during assembly, then returns to the enclosed state after aiming. The resilient member enables automatic retraction to the enclosed position, providing dynamic security.
Solution Approach 2:
The holder acts as an intermediary component that temporarily exposes the adjuster cap during assembly. Once the aiming function is fulfilled, the holder is removed, and the adjuster cap retracts, eliminating the intermediary access path.
3Reliability
If facilities and tooling are added to error proof the disabling process, then recall risks are reduced, but investment and complexity increase
Solution Approach 1:
The mechanism provides self-service error proofing through automatic retraction. When the holder is removed, the resilient member automatically returns the adjuster cap to the enclosed position without requiring additional tools, facilities, or manual intervention, thereby preventing errors at no additional complexity.
Solution Approach 2:
The holder is designed as a temporary, simple component that serves its purpose during assembly and is then discarded or removed. This disposable approach eliminates the need for complex permanent error-proofing facilities while ensuring the adjuster becomes secure after use.
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
Enables efficient headlamp aiming during vehicle production with minimal labor and cost, ensuring the position cannot be altered by end users, reducing recall risks and simplifying the disabling process.
Implementation Method 1
the headlamp adjuster assembly includes a resilient member that biases the adjuster cap to the stowed position
Data Source
AI summary
An apparatus, according to an exemplary aspect of the present disclosure includes, among other things, a lamp housing that houses a headlamp adjuster assembly moveable between an adjustment position and an inaccessible stowed position within the lamp housing, and a holder to hold the headlamp adjuster assembly in the adjustment position. The holder is selectively removable such that the headlamp adjuster assembly retracts to the inaccessible stowed position. A method according to an exemplary aspect of the present disclosure includes, among other things, biasing a headlamp adjuster toward the inaccessible stowed position, installing the holder to hold the headlamp adjuster external to the lamp housing against the biasing force, adjusting a position of a headlamp with the headlamp adjuster, and removing the holder such that the headlamp adjuster retracts to the inaccessible stowed position.