Automotive Headlamp Module DC Motor Shield Fail-Safe
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Solution Overview
Problem
Automotive headlamp modules with high-beam and adaptive driving-beam modes are costly and complex, leading to reduced safety during fail-safe functions, as they require expensive stepping motors and complex control logic, resulting in inadequate visual range and potential field obstruction in fail-safe modes.
Innovation Solution
A simplified automotive headlamp module using a DC motor instead of a stepping motor, coupled with a return spring and stoppers to adjust the beam pattern, allowing for low-cost production and implementation of low-beam mode during fail-safe functions in high-beam or ADB modes, ensuring adequate driver visibility and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a stepping motor is used to accurately adjust the rotational angle of the shield, then beam pattern control precision is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent replaces the expensive stepping motor with a simple DC motor that can be easily replaced. The shield's rotational position is controlled by simple mechanical stoppers (first and second stoppers) that define fixed positions for low-beam and high-beam modes, eliminating the need for expensive precision motors and complex control systems while maintaining functional beam pattern control.
Solution Approach 2:
The patent divides the shield into a shield body and a shield disc that can rotate independently. The shield disc is segmented to allow rotation between fixed positions defined by stoppers, enabling discrete beam pattern switching without requiring continuous precision control. This segmentation simplifies the motor requirements from precision-stepping to simple rotational actuation between defined positions.
2Manufacturing precision
If a stepping motor and sensor system is used for precise shield rotation, then beam pattern accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the expensive stepping motor with a simple DC motor that can be easily replaced. The shield's rotational position is controlled by simple mechanical stoppers (first and second stoppers) that define fixed positions for low-beam and high-beam modes, eliminating the need for expensive precision motors and complex control systems while maintaining functional beam pattern control.
Solution Approach 2:
The patent employs a return spring that automatically returns the shield disc to its initial position (low-beam mode) when power is removed or in case of motor failure. This self-service mechanism eliminates the need for expensive sensors and complex control logic to detect and correct position, as the mechanical spring automatically restores the safe default position.
3Reliability
If the fail-safe function lowers the beam pattern substantially proximate to the ground, then component protection is improved, but driver visual range deteriorates
Solution Approach 1:
The patent dynamically switches between two beam pattern positions: low-beam mode (shield disc in initial position) and high-beam mode (shield disc rotated to second position). The fail-safe function dynamically returns to the low-beam position, which provides adequate illumination without being substantially proximate to the ground, thus maintaining driver visual range while protecting components.
Solution Approach 2:
The return spring provides beforehand cushioning by automatically returning the shield disc to the low-beam position in case of motor failure or power loss. This pre-configured mechanical recovery mechanism ensures the headlamp maintains adequate illumination for driver visibility without requiring complex sensors or control systems, thus cushioning against the harmful effect of complete system failure.
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
The solution reduces manufacturing costs and enhances safety by enabling a sufficient visual range for drivers during emergencies by implementing a low-beam mode upon fail-safe function engagement, without the need for expensive sensors or complex control logic, making the technology feasible for common low-cost vehicles.
Implementation Method 1
a return spring having both ends supported by the shield housing and the housing disc that press the housing disc to the shield disc utilizing the accumulated elastic force
Data Source
AI summary
An automotive headlamp module thatreduces manufacturing cost and increases availability for low-cost vehicles is provided. The automotive headlamp provides a rotational force to a shield via a DC motor and improves safety during operation by implementing a beam pattern in a low-beam mode when performing a fail-safe function due to breakdown in a high-beam mode or an ADB mode. In particular, the automotive headlamp includes a drum type shield rotatably disposed with respect to a shield housing and has a high-beam protrusion, a low-beam protrusion, and an adaptive driving-beam (ADB) protrusion on an exterior side and a shield disc coupled to the shield that rotates. A housing disc guide is movable in a longitudinal direction of the shield by the shield housing and has an end in contact with the shield disc and a return spring and presses a housing disc to the shield disc with accumulated elastic force.