Integrated Bearing Holder for Vehicle Headlamp Bracket Stress
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Solution Overview
Problem
Existing vehicle headlamp designs face issues with increased parts and potential damage to the bracket due to the independent configuration of the spring member and bearing holding portion, which can lead to mechanical stress and backlash.
Innovation Solution
The integration of a spring member, bearing holding portion, and fixing portion into a single unit, with a design that eliminates the distance between the compression point and the bracket fixing portion, using a metal plate-formed bearing holder with a spring portion that compresses the upper support shaft, thereby preventing bracket damage and reducing part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the spring member and bearing holding portion are configured as separate independent parts, then the spring member can be installed independently, but the number of parts increases and the structure becomes more complex
Solution Approach 1:
The patent combines the spring member and bearing holding portion into a single integrated component called a bearing holder. The spring portion is formed as an integral part of the bearing holder, which also includes the bearing holding portion and fixing portion. This merging eliminates the need for separate installation of multiple parts while reducing overall structural complexity.
2Ease of operation
If the spring member is configured as an independent part, then installation flexibility is maintained, but mechanical stress concentrates on the bracket causing potential damage
Solution Approach 1:
By integrating the spring member with the bearing holding portion and fixing portion into a unified bearing holder structure, the mechanical stress is distributed across the entire integrated component rather than being concentrated on the bracket. The fixing portion of the bearing holder directly anchors the integrated spring member, eliminating stress concentration points on the bracket.
Solution Approach 2:
The spring portion is configured with a specific spatial arrangement where it extends from the bearing holding portion. This dimensional configuration allows the spring to absorb mechanical stress through its elastic deformation while the integrated structure distributes this stress away from the bracket, preventing damage.
3Manufacturing precision
If the distance between compression point and bracket fixing portion is increased, then installation tolerance is improved, but a moment is generated in the spring member causing backlash
Solution Approach 1:
The bearing holder integrates the bearing holding portion, spring portion, and fixing portion into a single rigid structure. This integration ensures that the distance between the compression point and fixing portion remains substantially zero, eliminating moment generation in the spring member and preventing backlash while maintaining precise positioning.
Solution Approach 2:
Instead of allowing a distance between the compression point and bracket fixing portion to accommodate installation tolerance, the patent inverts the approach by making the bearing holder itself the fixed reference. The fixing portion of the bearing holder is directly mounted to the bracket, and the spring portion is configured relative to this fixed point, ensuring zero distance and no moment generation.
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 mechanical stability, reduces the risk of bracket damage, and simplifies the design by eliminating the need for additional parts, ensuring reliable operation and reduced mechanical stress during swivel and leveling operations.
Implementation Method 1
a spring portion (42) adapted to compress a tip end of the upper support shaft (22)
Data Source
Figure 1(a)~1(e)
Figure 2(a)~2(b)
Figure 3
AI summary
An AFS-type vehicle headlamp (1) is provided, and includes a bearing holder (44) adapted to hold a bearing (41) that is inserted into an upper support shaft (22) of a lamp unit (10). The bearing holder (44) is formed integrally with a fixing portion for a bracket (30), a bearing holding portion (44) adapted to hold the upper support shaft (22), and a spring portion (42) adapted to compress a tip end of the upper support shaft (22). The fixing portion includes the bearing holding portion (44) adapted to hold the bearing (41) on a flat plate member in such a manner that a center of the bearing (41) is positioned in a plane that includes the flat plate member.