Bowden Cable Headlamp Leveler with Independent Manual Adjustment
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Solution Overview
Problem
Cable correctors for motor vehicle headlamps face issues due to slack introduced by the cable, leading to inconsistent force requirements across different correctors, which affects the range correction mechanism, and the initial manual adjustment influences subsequent cable adjustments, resulting in dispersion of forces and torque requirements.
Innovation Solution
A cable range corrector design where the initial manual adjustment does not affect the return spring, allowing subsequent adjustments by cable to be independent, utilizing a ring gear and drive pinion mechanism to ensure the carriage and rod move independently of the cable length, thereby maintaining consistent torque during dashboard control button rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cable corrector is used to reduce cost compared to electric correctors, then the cost is reduced, but slack is introduced by the cable leading to inconsistent force requirements
Solution Approach 1:
The corrector is divided into two independent adjustment systems: manual adjustment for initial positioning and cable adjustment for operational correction. This segmentation allows each system to be optimized independently, with the manual adjustment establishing a predetermined spring compression that compensates for cable slack, thereby ensuring consistent force requirements during cable operation.
Solution Approach 2:
The manual adjustment is performed as a preliminary action during vehicle assembly to pre-compress the spring and position the carriage. This preliminary positioning accounts for and compensates for the inherent cable slack, ensuring that subsequent cable adjustments operate from a known, consistent starting point with predictable force requirements.
2Manufacturing precision
If manual adjustment is performed to overcome tolerances and ensure proper positioning, then positioning accuracy is improved, but the spring compression varies between correctors leading to dispersion of forces
Solution Approach 1:
The manual adjustment serves as a preliminary action that establishes a standardized spring compression across all correctors. By following a standardized procedure to position the carriage and compress the spring to a predetermined level, the invention eliminates force dispersion while maintaining positioning accuracy.
Solution Approach 2:
The invention changes the parameter of spring compression from a variable determined by individual manual adjustments to a standardized parameter established by a predetermined compression level. This parameter change ensures that all correctors operate with consistent force characteristics regardless of manufacturing tolerances.
3Force
If the spring is oversized to accommodate variations in manual adjustment, then force consistency is improved, but the control torque range becomes excessive
Solution Approach 1:
The invention changes the spring selection criterion from oversized design to predetermined compression level. By establishing a specific compression level during manual adjustment, the spring can be properly sized, resulting in both force consistency during operation and an optimized, non-excessive control torque range.
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 design dissociates initial manual adjustment from subsequent cable adjustments, providing a working torque independent of the initial manual adjustment, avoiding the need for oversized springs and tightening the control torque range, ensuring consistent and efficient range correction of the headlamp beam.
Implementation Method 1
a return spring (28) which pushes the carriage (12) and the tilting push rod (13)
Implementation Method 2
the cable (18) on which the conductor of the vehicle can pull more or less with the aid of a control and adjustment device
Data Source
Figure 1~2
Figure 3~4
AI summary
The device has a traction and adjustment cable (118) anchored on a carriage (109) and driving an actuating rod (113) against action of a return spring (128). A manual rod position adjustment unit is formed of a rotary pinion (120) and an adjustment sleeve (114), and translationally drives the rod. The unit has a connection between the sleeve and an element of the carriage and arranged such that rotation of the sleeve translationally drives the element. A case (111), a shank (112) and the rod are arranged such that the unit drives the rod without modifying a state of the spring.