Adjustable Low-Beam Reflector Alignment in Vehicle Headlamps
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Solution Overview
Problem
Existing automotive headlight systems require precise manufacturing and assembly of identical low-beam modules to align light distributions, leading to complex and costly production processes due to stringent alignment requirements.
Innovation Solution
A vehicle headlight design with adjustable low-beam module reflectors that can be rotated around a focal point, allowing for larger manufacturing tolerances and precise alignment during assembly, using a robust adjustment mechanism with a guide section and engagement section for continuous adjustment and fixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple identical low-beam modules are used, then the light distribution can be generated, but the manufacturing and assembly precision requirements become extremely stringent to align the cut-off lines
Solution Approach 1:
The reflector is made adjustable through a rotation mechanism that allows it to be rotated around the focal point of the light source. This dynamic adjustment capability enables the cut-off line to be aligned precisely during assembly without requiring extremely tight manufacturing tolerances, thereby reducing manufacturing costs while maintaining alignment precision.
Solution Approach 2:
The invention changes the positional parameter of the reflector by allowing rotation around the focal point. This parameter change enables the reflector to be positioned at different angles to achieve precise cut-off line alignment, transforming a precision manufacturing problem into a simpler adjustment problem.
2Manufacturing precision
If the reflector position is adjusted during assembly, then the alignment precision of light distribution can be improved, but the device complexity increases
Solution Approach 1:
The adjustment mechanism is segmented into distinct functional components: a guide section with a cup-shaped or cylindrical segment-shaped surface, an engagement section with a corresponding shape, and a fastening screw. This segmentation allows each component to perform its specific function while keeping the overall mechanism simple and easy to manufacture.
Solution Approach 2:
The guide section and engagement section are designed with complementary cup-shaped or cylindrical segment-shaped surfaces that enable self-alignment and positive engagement. The fastening screw automatically secures the reflector in the desired position, eliminating the need for complex adjustment mechanisms or specialized tools.
3Manufacturing precision
If conventional adjustment mechanisms that deform the reflector are used, then the alignment can be adjusted, but the light distribution is distorted and legal requirements may not be met
Solution Approach 1:
Instead of deforming the reflector, the invention dynamically rotates the entire reflector around the focal point as a rigid body. This rotational movement changes the orientation of the reflector without altering its shape or the light distribution pattern it produces, ensuring compliance with legal requirements while achieving alignment adjustability.
Solution Approach 2:
Conventional mechanisms deform the reflector to achieve adjustment, but this invention inverts the approach by rotating the reflector around the focal point. This inversion maintains the reflector's original shape and optical properties while achieving the desired alignment adjustment, thereby preserving light distribution integrity and legal compliance.
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
Enables cost-effective manufacturing and assembly by allowing for larger manufacturing tolerances while ensuring precise light distribution alignment, avoiding defocusing issues and compliance with legal requirements.
Implementation Method 1
Each low-beam module (2) comprises a reflector (2a) with at least one focal point (P) or a focal line. The at least one light source (4) is arranged at the focal point (P) or the focal line of the reflector (2a).
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a motor vehicle headlamp (1) with an adjustable low beam, comprising at least two low-beam modules (2) for joint emission of a low-beam distribution, with each low-beam module (2) respectively being configured to emit a portion of the low-beam distribution with a specifiable luminous intensity, at least one light source carrier (3) with light sources (4), at least one light source (4) being assigned to each low-beam module (2), each low-beam module (2) comprising a reflector (2a) with at least a focal point (P) or a focal line, and at least one light source (4) being arranged on the focal point (P) or a focal line of the reflector (2a), and each low-beam module reflector (2a) being designed such that the light distribution emitted by each low-beam module (2) and also the light/dark boundary of the respective low-beam distribution are conclusively defined in conjunction with the assembled position of the low-beam module reflector (2a), the low-beam module reflector (2a), for the purposes of defining the course of a light/dark boundary of the respective portion of the low-beam distribution, having at least one edge (K) in the reflector surface reproducing this boundary, and at least one heatsink (5), on which the light source carrier (3) and the low-beam modules (2) are fastened, with at least one of the low-beam module reflectors (2a, 2a2) being securely connectable to the heatsink (5) in adjustable fashion by way of a reflector holder (2b) in each case, each reflector holder (2b) having at least one guide section (2b'), and each adjustable low-beam module reflector (2a2) having a corresponding engaging section (2a') for engagement in the guide section (2b'), the guide section (2b') of the reflector holder (2b) being designed such that a low-beam module reflector (2a2) engaging with the reflector holder (2b) can be continuously rotated along a section of a circular trajectory (B) and can be set and fixed in any relative rotational position in relation to the reflector holder (2b) within a rotational range defined thereby, the guide section (2b') being designed in such a way in the process that the center of the circular trajectory coincides with the focal point (P) of the adjustable low-beam module reflector (2a2) or is located on the focal line of the adjustable low-beam module reflector (2a2).