Motor Vehicle Headlamp Projection Optics Positioning
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Solution Overview
Problem
Existing motor vehicle headlight lighting devices require complex positioning devices for precise lens placement, leading to high manufacturing costs and limitations to non-rotationally symmetrical lenses due to long tolerance chains.
Innovation Solution
A reference point system defined in the receiving means, following the 3-2-1 rule, is used to determine the position of the projection optics, allowing for simplified and accurate positioning without complex devices, enabling the use of non-rotationally symmetrical lenses and reducing tolerance chains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex positioning devices are used for precise lens placement, then positioning accuracy is improved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent replaces complex mechanical positioning devices with a reference point system that uses simple geometric references (planes, lines, points) defined in the receiving means. The projection optics are positioned by aligning with these reference points rather than using complex mechanical positioning mechanisms, thereby reducing device complexity while maintaining positioning accuracy.
Solution Approach 2:
The patent changes the positioning approach from mechanical adjustments to a reference-based system where the position is determined by geometric parameters (reference planes, lines, and points). This parameter change allows for simplified positioning without sacrificing precision, as the reference points provide unambiguous positional information.
2Manufacturing precision
If complex positioning devices are used for precise lens placement, then positioning accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive complex mechanical positioning devices with a simple reference point system that can be manufactured into the receiving means itself. This substitution dramatically reduces manufacturing cost while maintaining the ability to achieve precise lens positioning through the reference planes, lines, and points.
Solution Approach 2:
The receiving means defines its own reference points system, making the positioning function self-contained within the component itself rather than requiring external complex positioning devices. This self-service approach eliminates the need for additional expensive positioning mechanisms and simplifies the overall manufacturing process.
3Manufacturing precision
If rotationally symmetrical lenses are used with complex positioning devices, then positioning accuracy is improved, but adaptability to different lens types decreases
Solution Approach 1:
The reference point system is designed to be universal and can accommodate different types of projection optics including rotationally symmetrical and non-rotationally symmetrical lenses. The reference planes, lines, and points provide a flexible framework that can be adapted to various lens geometries, making the positioning system versatile rather than limited to specific lens types.
Solution Approach 2:
The patent explicitly enables the use of non-rotationally symmetrical projection optics by using a reference point system that does not assume rotational symmetry. The reference planes, lines, and points can define positions for asymmetric lenses just as effectively as for symmetric ones, thereby increasing adaptability to different lens types.
4Device complexity
If a reference point system with 3-2-1 rule is used, then device complexity is reduced, but positioning precision may be compromised
Solution Approach 1:
The patent substitutes complex mechanical positioning with a mathematically rigorous reference point system based on the 3-2-1 rule. This system uses three reference planes, two reference lines, and one reference point to completely define the position of the projection optics, providing sufficient precision without mechanical complexity.
Solution Approach 2:
The reference points act as intermediaries between the receiving means and the projection optics, providing a precise mathematical framework for positioning. The 3-2-1 rule reference system serves as an intermediary that translates geometric relationships into accurate positional information, maintaining precision while simplifying the overall system.
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 approach reduces manufacturing costs and improves image sharpness and optical quality by allowing precise adjustment of the focal plane, compensating for lens shape deviations and thickness tolerances, while accommodating different projection optics and sizes.
Implementation Method 1
a lens (1) for projecting a lighting pattern (LI), producible by means of this at least one light source (2), in the form of a light distribution in front of the lighting device
Data Source
AI summary
Lighting device of a motor vehicle headlamp, comprising a lens (1, 10) and at least one light source (2), wherein a lighting pattern (LI) can be generated by the at least one light source (2), wherein the lighting pattern (LI) generated by the light source (2) can be projected in front of the lighting device in the form of a light distribution by means of the lens (1, 10), wherein the lens (1, 10) has at least one projection optics (3, 30, 31) and one projection optics holder (4, 40), wherein at least one receiving means (5, 50, 51) is designed in the projection optics holder (4, 40), wherein the at least one receiving means (5, 50, 51) corresponds to the at least one projection optics (3, 30, 31), the at least one projection optics (3, 30, 31) is accommodated in the at least one receiving means (5, 50, 51), wherein a reference point system (6, 60, 61) is defined in the at least one receiving means (5, 50, 51) for determining a position of the projection optics (3, 30, 31) accommodated in this receiving means (5, 50, 51) in such a way that the lighting pattern (LI) is essentially located in a focal plane of the lens (1, 10), wherein reference points (6-1 to 6-6, 60-1 to 60-16, 61-1 to 61-10) of the reference point system (6, 60, 61) are arranged according to the 3-2-1 rule, wherein the at least one receiving means (5, 50, 51) is closed by means of a closing element (7, 70) in such a way that the at least one projection optics (3, 30, 31) is fixed and held in the at least one receiving means (5, 50, 51) in the position determined by the reference point system (6, 60, 61).