Headlight Alignment Element for Stress-Free Z-Direction Fixing
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Solution Overview
Problem
Existing headlight fastening systems for motor vehicles face challenges in aligning and securing headlight structures without causing stress or distortion, often requiring additional tools and screws, which can complicate servicing and may lead to headlight trembling or inadequate structural support.
Innovation Solution
A headlight fastening system that uses a single-valued alignment element to align and fix the headlight structure in the z-direction, simultaneously securing it in the x and y directions without play, utilizing a plug-in/snap-in connection that requires no tools, allowing for stress-free alignment and fixing, and accommodating tolerances and assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single-value alignment element is used to align the headlight structure in the z-direction with clearance of approximately +/- 3 mm in x- and y-directions, then the alignment in z-direction is achieved, but the headlight structure develops severe headlight flicker and cannot structurally support the fender connection
Solution Approach 1:
The patent combines the alignment function and the support function into a single integrated alignment element. The alignment element not only aligns the headlight structure in the z-direction but also provides structural support for the fender connection, eliminating the need for separate support structures and preventing headlight flicker while maintaining alignment precision.
Solution Approach 2:
The alignment element is designed to perform multiple functions simultaneously: it aligns the headlight structure in the z-direction, provides structural support for the fender connection, and prevents headlight flicker. This multi-functional design resolves the contradiction by making the alignment element universally responsible for both precision alignment and structural stability.
2Strength
If screws are commonly used to tighten the alignment element, then the connection is secured, but access to the screw may be impossible during servicing and the fastening cannot be loosened
Solution Approach 1:
The alignment element is designed with a self-locking mechanism that does not require separate screws or tools for fastening. The element automatically secures itself through its own structural design, eliminating the need for additional fastening components and enabling easy servicing without requiring access to hidden screws.
Solution Approach 2:
The patent extracts the separate screw fastening mechanism from the alignment element design. By removing the need for external screws, the alignment element can be directly fastened and serviced without requiring tool access to hidden fasteners, thus improving serviceability while maintaining connection strength.
3Ease of manufacture
If the third fixing is allowed a clearance of approximately +/- 3 mm with respect to the x- and y-directions, then assembly is simplified, but the headlight structure risks developing severe headlight flicker and cannot structurally support the fender connection
Solution Approach 1:
The patent merges the alignment function and the support function into a single integrated alignment element. The alignment element not only aligns the headlight structure in the z-direction but also provides structural support for the fender connection, eliminating the need for separate support structures and preventing headlight flicker while maintaining alignment precision.
Solution Approach 2:
The alignment element is designed to perform multiple functions simultaneously: it aligns the headlight structure in the z-direction, provides structural support for the fender connection, and prevents headlight flicker. This multi-functional design resolves the contradiction by making the alignment element universally responsible for both precision alignment and structural stability.
Data Source
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AI summary
The invention relates to a headlight mounting system (1) for a motor vehicle for mounting and aligning a headlight structure (S) to two support structures (T) of the motor vehicle with respect to, in particular, the x, y and z directions of the vehicle, comprising a single-valued alignment element (2) for mounting and aligning the headlight structure (S) in the z direction (z) to one of the support structures (T).In order to fix the single-value alignment element to the structures to be joined at least substantially stress-free, without play, and without the use of any additional tools, it is proposed that the headlight mounting system (1) be designed such that the structures to be joined (S, TF, TK) are arranged in an alignment position relative to each other, particularly with respect to the x, y, and z directions of the vehicle, via the single-value alignment element (2), and that moving the alignment element (2) from the alignment position to a fixing position for fixing the structures (S, TF, TK) in the z direction (z) simultaneously fixes them in the x direction (x) and y direction (y). The invention further relates to a method for using this headlight mounting system (1).