Vehicle Headlight Ball Joint Control Contour Locking
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Solution Overview
Problem
Existing ball joints for vehicle headlights have low locking torques, are cumbersome to assemble, and prone to material fatigue, leading to high service costs and premature wear due to insufficient fixation force, especially under vibrations and temperature fluctuations.
Innovation Solution
The use of control contours on the joint sleeve and socket, which exert radial and axial forces to securely fix the joint ball, enhancing the locking torque and tolerance to component inaccuracies, while allowing easy disassembly and reducing material stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional ball joint is used to fix the vehicle headlight, then the assembly is simple and can accommodate tolerances, but the locking torque is low and the holding force is insufficient under vibrations and temperature fluctuations
Solution Approach 1:
The patent applies local quality by introducing control contours (raised features) at specific locations on the joint ball and corresponding control surfaces on the joint socket. These localized geometric features concentrate the locking force at critical points, creating high contact pressure exactly where needed to prevent loosening under vibration, while the rest of the ball joint structure remains simple and easy to assemble.
Solution Approach 2:
The patent utilizes the spherical geometry of the joint ball by positioning control contours on its surface that interact with control surfaces on the joint socket. The curved surfaces of the ball and socket naturally distribute forces, while the added control contours create localized engagement points that enhance locking torque through their geometric interaction during rotation and settling.
2Ease of repair
If a conventional ball joint is used, then assembly is straightforward, but disassembly is cumbersome and may destroy the socket, leading to material fatigue and premature wear
Solution Approach 1:
The patent segments the locking function from the main ball joint structure by using separate control contours and control surfaces that engage through geometric interference rather than permanent deformation. This segmentation allows the joint to be assembled and disassembled multiple times without damaging the socket, as the control contours can be engaged and disengaged cleanly without destroying the socket material.
3Reliability
If the joint socket is pressed firmly onto the joint ball to increase locking force, then the holding force improves, but the assembly process becomes more difficult and requires higher forces
Solution Approach 1:
The patent applies preliminary action by designing control contours with leading edges that guide the assembly process. As the joint socket is approached toward the joint ball, the control contours make initial contact first, guiding the components into proper alignment and beginning the locking action before the full weight of the socket is applied. This preliminary engagement reduces the force needed during final assembly.
Solution Approach 2:
The spherical shape of the joint ball combined with the geometric design of control contours allows for self-aligning during assembly. The curved surfaces guide the components into their correct relative positions as they come together, reducing the precision required during assembly and lowering the forces needed to achieve proper engagement compared to flat or irregular surfaces.
Data Source
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AI summary
Vehicle headlight (1) comprising a ball joint (200), a light module (2) and a support frame (20), wherein the ball joint (200) connects the support frame to the light module (2) or a vehicle-side support unit, wherein the ball joint (100, 200) is fixable in a joint position, and the ball joint (100, 200) comprises: a joint pin (110) comprising a joint ball (111) which on one side transitions into an end face of an substantially cylindrical joint shaft (112).Furthermore, a joint socket (220) for receiving the ball joint (111) is included, wherein the joint socket (220) comprises at least two, preferably three, wings (221) arranged successively along the circumference of the joint socket (220) and, in the fixed state of the ball joint (200), forming an inner joint surface of the ball joint (200) on the ball joint (111) and enclosing the ball joint (111), which, in the fixed state of the ball joint (200), is shaped complementary to the surface of the ball joint (111). A joint sleeve (140) for receiving the joint socket (220) is also included, wherein the joint sleeve (140) at least partially encloses the wings (221) of the joint socket (220).The ball joint (200) comprises at least one control contour (146; 226) which is designed to exert a radial clamping force on the ball joint (111) by means of a rotational movement between the socket joint (220) and the sleeve joint (140) through the wings (221) of the socket joint (220) and thereby fix the ball joint (200).