Headlight Adjustable Support Structure Using Threaded Spindles
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Solution Overview
Problem
There is a conflict between achieving a compact design and a large adjustment range for headlight systems, as existing solutions either result in a large headlight housing due to the need for extensive adjustment paths or complicate the adjustment process, especially with LED light engines.
Innovation Solution
An adjustable support structure using threaded spindles and bushings allows for variable axial adjustment of optical components, enabling a wide range of light emission angles without increasing the headlight's size, with a mechanism that includes a coupling device, drive components, and a traction mechanism to precisely control the position of the optical component carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the lens is positioned deep within the headlight housing to allow for large adjustment range, then the adjustment range is improved, but the headlight housing diameter must be increased to avoid vignetting
Solution Approach 1:
Instead of moving the lens deep within the housing along the optical axis to achieve adjustment, the patent inverts the approach by positioning the lens at the front of the housing and moving the light source and other components (reflector, wiring, heat sink, fan) relative to the lens. This allows large adjustment range while maintaining a compact housing diameter and avoiding vignetting.
Solution Approach 2:
The patent implements a dynamic adjustment mechanism where the light source and associated components are movable relative to the fixed lens at the front. This dynamic configuration allows the system to achieve various beam patterns (spot, flood, and intermediate settings) without requiring a large housing diameter, as the adjustment is achieved through relative motion rather than deep lens positioning.
2Adaptability or versatility
If the lens is moved along a large adjustment path to achieve different lighting effects, then the adjustment range is improved, but the headlight housing length along the optical axis increases
Solution Approach 1:
The patent inverts the traditional adjustment approach by keeping the lens fixed at the front of the housing and instead moving the light source and other components along the optical axis. This allows the same adjustment functionality to be achieved without increasing the housing length, as the effective adjustment path is created by the relative motion of components rather than the physical depth of the housing.
3Object-affected harmful factors
If the headlight housing is enlarged to accommodate deep lens positioning and avoid vignetting, then vignetting is prevented, but the overall headlight size increases
Solution Approach 1:
The patent prevents vignetting without enlarging the housing by inverting the adjustment mechanism: the lens is positioned at the front of the housing where it can receive full light from the source, and the light source itself is made movable relative to the lens. This allows optimal lens-to-source positioning for each beam mode while maintaining a compact housing volume.
Solution Approach 2:
The patent segments the headlight system into a fixed front portion (lens and housing opening) and a movable rear portion (light source, reflector, wiring, heat sink, fan). This segmentation allows the lens to remain in a fixed position that prevents vignetting while the movable components provide adjustment functionality, avoiding the need to enlarge the entire housing.
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 solution allows for a compact headlight design with a large adjustment range, preventing vignetting and simplifying the adjustment process, particularly suitable for LED headlights by maintaining a compact form while allowing for seamless transitions between spot and flood settings.
Implementation Method 1
The adjustment device comprises four threaded spindles (28), each having a first threaded spindle end (28a) and a second threaded spindle end (28b)... The connection of the threaded spindles (28) to the coupling device (20) is effected via threaded bushings (30)... All threaded spindles (28) run essentially parallel to the optical axis (24).
Data Source
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AI summary
An adjustable support structure (12) for a headlight (10) is described. This structure comprises an optical component carrier (14) to which an optical component (16) can be attached, a coupling device (20) for attaching the support structure (12) to the headlight (10), and at least one threaded spindle (28). The latter has a first threaded spindle end (28a) that is axially and rotationally fixed to the optical component carrier (14) and is connected to the coupling device (20) via a threaded bushing (30) that cooperates with the threaded spindle (28). The threaded bushing (30) is axially fixed and rotatably connected to the coupling device (20). The threaded spindle (28) runs essentially parallel to an optical axis (24) of the adjustable support structure (12). The distance between the first threaded spindle end (28a) and the coupling device (20) can be adjusted by rotating the threaded bushing (30).Furthermore, a headlight (10) with such a support structure (12) is presented.