Vehicle Headlamp Optical Unit Locking Body for Low-Cost Adjustment
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Solution Overview
Problem
Existing headlamp designs with adjustable optical units have high manufacturing costs due to complex adjustment devices that require high manufacturing effort.
Innovation Solution
The introduction of a locking body with a base element and locking/fastening means that is connected to the optical unit, allowing for tool-free assembly and enhanced vibration resistance, reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the receiving part is integrally connected to the housing and the fastening part is integrally connected to the optical unit, then the adjustment device provides stable and reliable connection, but the manufacturing effort and manufacturing costs are relatively high
Solution Approach 1:
The receiving part is divided into a separate locking body that can be inserted into the fastening part. This segmentation allows the locking body to be manufactured independently and then assembled, reducing the manufacturing effort and costs while maintaining the reliable connection through the locking mechanism with expansion elements and locking means.
Solution Approach 2:
The locking body acts as an intermediary element between the housing and the optical unit. It provides a dedicated locking and fastening interface that ensures stable connection while allowing for simpler manufacturing of each component separately, thus resolving the contradiction between connection reliability and manufacturing ease.
2Adaptability or versatility
If a threaded screw with ball joint is used for adjustment, then the optical unit can be adjusted relative to the housing, but the device complexity increases
Solution Approach 1:
The ball joint and threaded screw are integrated into a single adjustment device assembly that connects the locking body to the optical unit. This merging reduces the number of separate components and simplifies the overall adjustment mechanism while maintaining the ability to adjust the optical unit's position and angle.
Solution Approach 2:
The adjustment device with threaded screw and ball joint serves multiple functions: it provides both angular adjustment and positional adjustment of the optical unit. This multi-functionality reduces the need for separate adjustment mechanisms, thereby reducing device complexity while maintaining adaptability.
3Ease of operation
If the locking body has expansion elements that are resiliently connected, then the assembly can be done without tools and vibration resistance is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The expansion elements are designed to be resilient and movable, allowing them to dynamically adapt to the fastening part during assembly. This dynamic design enables tool-free assembly as the expansion elements can be compressed and locked into place without precision tools, while the resilient connection maintains manufacturing precision through elastic recovery and controlled deformation.
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 the stability of the adjustment mechanism, enabling tool-free assembly and improved resistance to oscillation and vibration.
Implementation Method 1
The expansion elements are resiliently connected to the base element so that they can be moved (resiliently) transversely to the swivel axis or transversely to the threaded screw
Implementation Method 2
The threaded screw is then linearly guided in the locking body, forming a threaded engagement, wherein the expansion elements are pressed against the inner wall of the fastening part
Implementation Method 3
The locking and/or fastening means are configured in such a way that, in this assembled position, the locking body is connected to the fastening part in a positionally secure manner as well as being without play, and is resistant to oscillation and vibration
Data Source
AI summary
This invention relates to a headlamp for vehicles, comprising a housing in which a light source and an optical unit are arranged for producing a specified light distribution, wherein the optical unit is arranged so as to be movable via an adjustment device with respect to a horizontal and/or vertical axis, and the adjustment device comprises a threaded screw, which is coupled via a ball joint to the housing or to a support frame fastened to the housing, and a threaded shank of the threaded screw is in threaded engagement about a rotational axis with a receiving part, wherein the receiving part is insertable into a fastening part integrally connected to the optical unit, wherein the receiving part is a locking body with a base element extending perpendicularly to the rotational axis and a plurality of locking and/or fastening means projecting from the base element.