Vehicle Headlamp Shear-Pin Mounting for Impact Release
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Solution Overview
Problem
Existing vehicle headlamp attachment systems do not effectively absorb and distribute impact forces, potentially causing damage to the headlamp and other objects during collisions.
Innovation Solution
An apparatus that secures headlamps to a vehicle's front end module, featuring a base that engages the headlamp housing, a connector for tolerance compensation, and a shear pin fastener that breaks upon impact, allowing the headlamp to move and absorb force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid attachment system is used to secure headlamps, then the headlamp is firmly fixed to the vehicle, but the impact force is transmitted directly causing damage to the headlamp and other objects
Solution Approach 1:
The attachment system transitions from a static rigid connection to a dynamic system where the shear pin can fail and the headlamp can move. The fastener is designed with a specific shear strength that allows it to break under impact forces, enabling the headlamp to move and absorb impact energy rather than transmitting it rigidly to other components.
Solution Approach 2:
The shear pin is designed to fail under impact conditions, converting the harmful impact force into a beneficial outcome. When the shear pin breaks, it allows the headlamp to move and absorb the impact energy, protecting other vehicle components from damage. The controlled failure of the shear pin transforms the harmful impact into a protective mechanism.
2Object-affected harmful factors
If a shear pin fastener is used to allow headlamp movement upon impact, then damage to other objects is minimized, but the attachment system becomes more complex
Solution Approach 1:
The attachment system is segmented into distinct functional components: the base mechanism for securing the headlamp, the shear pin fastener for controlled failure, and the connector for tolerance compensation. This segmentation allows each component to perform its specific function independently, simplifying the overall design while achieving the desired impact protection.
Solution Approach 2:
The shear pin acts as an intermediary element between the base and the connector. It provides a controlled failure point that mediates the transmission of impact forces, allowing the system to protect other components while maintaining a relatively simple overall structure. The shear pin is a simple mechanical element that adds minimal complexity while providing the desired protective function.
3Object-affected harmful factors
If the fastener is designed to break upon impact, then the headlamp can move to reduce counterforce, but the reliability of the attachment system decreases
Solution Approach 1:
The shear pin is pre-designed with a specific shear strength that is lower than the strength of other components in the system. This preliminary design decision ensures that under impact conditions, the shear pin will fail first, allowing the headlamp to move and reduce counterforce to impacted objects. The controlled failure is built into the design from the beginning.
Solution Approach 2:
The shear pin has localized properties that differ from other components in the attachment system. It is designed with specific material properties and dimensions that give it a lower shear strength, creating a controlled weak point. This local quality difference ensures that the shear pin fails first under impact, protecting the overall system while maintaining reliability for normal operating conditions.
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 apparatus minimizes damage to the headlamp and other objects by allowing the headlamp to move upon impact, reducing the force transmitted to the impacted object and enabling easy reinstallation by replacing the shear pin.
Implementation Method 1
In the event of impact to the housing, the fastener may shear, or break, thus allowing the housing to move relative to the attachment
Data Source
AI summary
An apparatus secured to a lamp of a vehicle is designed to release the lamp upon impact to the lamp. The apparatus may secure with a lamp housing as well as with a front end module of a vehicle. The apparatus may include a fastener that secures with the lamp housing. When the lamp is impacted, the fastener may shear (e.g., break), thus allowing displacement of the headlamp. As a result, pedestrians and/or objects impacting the lamp are less likely to incur damage. Moreover, the lamp is less likely to be damaged, and may be reinstalled when the fastener is replaced.