Motor Vehicle Headlight Support Frame Alignment Mechanism
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Solution Overview
Problem
Conventional headlight designs for motor vehicles face difficulties in assembly and quality control due to complex coupling points between adjustment and coupling elements, leading to unwanted shifts of partial light fields during beam range adjustments.
Innovation Solution
A joint piece with a ball socket is integrated into the first support frame, allowing the ball head of the coupling element to be aligned coaxially with the adjustment element's axis, enabling synchronous tilting of support frames without light field deviations, and featuring a fastening portion for secure attachment and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a complex multi-part coupling point is used to connect adjustment and coupling elements, then the support frames can be adjusted, but assembly and quality control become difficult and require increased experience
Solution Approach 1:
The coupling point is segmented into separate functional elements: a coupling element with ball head for connecting support frames, and a separate adjustment element with its own ball head for beam range adjustment. This segmentation eliminates the need for complex multi-part coupling points while maintaining adjustability functionality.
Solution Approach 2:
The patent introduces a joint piece as an intermediary component that connects the adjustment element to the first support frame. This joint piece features a ball socket that receives the adjustment element's ball head, and its arrangement ensures the adjustment axis extends through the coupling element's ball head, simplifying the overall coupling mechanism.
2Manufacturing precision
If pivot points are configured point-by-point for connecting adjustment and coupling elements, then connections are established, but deviation of support frames during adjustment occurs causing axial offset of composite light fields
Solution Approach 1:
The patent merges the functional requirements of multiple pivot points into a single integrated joint piece. This joint piece simultaneously provides the connection point for the adjustment element and establishes the correct geometric relationship with the coupling element, ensuring both support frames remain aligned during adjustment without requiring separate pivot point configurations.
Solution Approach 2:
The joint piece acts as an intermediary that mediates between the adjustment element and coupling element. Its specific arrangement on the first support frame ensures that the adjustment axis extends through the coupling element's ball head, maintaining precise light field alignment while simplifying the pivot point configuration.
3Manufacturing precision
If the adjustment axis does not align with the coupling element's ball head, then assembly may be simpler, but light field deviations occur during support frame adjustment
Solution Approach 1:
The joint piece merges the alignment function with the connection function. By integrating the ball socket and fastening portion into a single component with a specific arrangement, it ensures the adjustment axis automatically aligns with the coupling element's ball head during assembly, achieving both precise light field alignment and assembly simplicity simultaneously.
Data Source
AI summary
A headlight for a motor vehicle having a first light module, which is received in a first support frame, and at least one second light module, which is received in a second support frame. A headlight range adjustment device has an adjustment element, which extends between the headlight range adjustment device and the first support frame in an adjustment axis. The adjustment element has a ball head, which is accommodated by a ball head receptacle on the first support frame. A joint piece with a ball socket is arranged on the first support frame, wherein in the ball socket, a ball head of a coupling element is received. An arrangement of the joint piece is formed on a first support frame, and the adjustment axis of the adjustment element runs in its extension through the ball head of the coupling element.