Motor Vehicle Headlamp Lever Mechanism for Optical Axis Adjustment
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Solution Overview
Problem
Current motor vehicle headlight systems face challenges in achieving high-resolution, homogeneous light projection due to assembly tolerances and imprecise adjustment of optical components, leading to issues like blurriness and inadequate light distribution.
Innovation Solution
The headlight design features a frame with a movably arranged projection optics and a lever system that allows for precise adjustment along the projection axis, utilizing a flexible spring element and adjustable connecting elements to compensate for assembly tolerances, enabling fine-tuned positioning of optical components without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fixed mounting of projection optics is used, then assembly is simple, but manufacturing precision and adjustment precision are insufficient leading to blurriness and poor light distribution
Solution Approach 1:
The projection optics are mounted on a movable frame that can be adjusted along the projection axis. The frame includes a lever mechanism with a pivot axis that allows the projection optics to be positioned precisely by rotating the lever, which moves a pressing element to apply controlled force. This dynamic mounting structure replaces fixed rigid mounting, enabling precise adjustment while maintaining structural simplicity.
2Manufacturing precision
If tight tolerances are required for optical components, then light projection quality improves, but assembly difficulty and time increase significantly
Solution Approach 1:
The lever mechanism is pre-configured with a pivot axis and pressing element that automatically provides precise positioning when assembled. The frame structure includes pre-positioned guides and mounting points that ensure correct alignment. This preliminary preparation of the mounting structure eliminates the need for time-consuming manual adjustment and tolerance checking during final assembly, achieving both precision and productivity.
3Measurement precision
If adjustment mechanisms are added to improve positioning precision, then light distribution quality improves, but device complexity increases
Solution Approach 1:
The adjustment function is segmented into simple rotational movement of the lever around a pivot axis, which translates to linear movement of the pressing element along the projection axis. This segmentation of the adjustment mechanism into basic mechanical components (lever, pivot axis, pressing element) achieves precise positioning without requiring complex multi-degree-of-freedom adjustment systems.
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 allows for highly precise adjustment of light sources, reflectors, and lenses, ensuring a compact and flexible headlight system that can project high-resolution images with improved light distribution and adaptability to various installation conditions.
Implementation Method 1
a lever which is rotatably connected to the holder by means of axial elements which form a pivot axis which runs transversely, preferably perpendicular to the projection axis, and the frame has at least one lug which is located between the holder and the lever, and the lever is arranged to press on the at least one lug when rotating about the pivot axis, and thereby move the frame in the holder along the projection axis
Implementation Method 2
utilizing a flexible spring element and adjustable connecting elements to compensate for assembly tolerances
Data Source
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AI summary
The invention relates to a motor vehicle headlamp (101) comprising a light source (105), projection optics (102, 202) and a bracket (106, 206), wherein the light source (105) is mounted on the bracket (106, 206) and is configured to project light in the direction of a projection axis (104, 204) by means of the projection optics (102, 202), wherein the projection optics (102, 202) are mounted in a frame (103, 203) which is movably arranged in the bracket (106, 206). The headlamp further comprises a lever (107, 207) which is rotatably connected, by means of axis elements that form a pivot axis running transversely or normal to the projection axis (104, 204), to the bracket (106, 206). The frame (103, 203) comprises at least one lug (110, 210) which is located between the bracket (106, 206) and the lever (107, 207), and the lever (107, 207) is configured, in the event of a rotational motion around the pivot axis, to press on the at least one lug (110, 210), and thereby to displace the frame (103, 203) in the bracket (106, 206) along the projection axis (104, 204).