Self-Aligning Bearing Actuator for Vehicle Headlight Rattle Elimination
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Solution Overview
Problem
Existing vehicle headlight actuators face challenges in maintaining stability and accuracy due to rattle issues and misalignment, particularly when adjusting light beam direction in response to changes in vehicle attitude or load, which affects the precision and reliability of light emission.
Innovation Solution
The actuator design incorporates a unique configuration with a short distance between the second worm and output shaft, utilizing a helical gear rack to secure the moving mechanism and reduce rattle, along with a self-aligning bearing mechanism and fixing member for improved alignment and stability, allowing precise movement of the output shaft and lamp unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the distance between the second worm and output shaft is increased to reduce the force conducted to the output shaft, then the rattle of the output shaft is eliminated, but the moving range of the output shaft is insufficient
Solution Approach 1:
The patent introduces a self-aligning bearing mechanism that adds a rotational degree of freedom to the bearing assembly. This allows the bearing to rotate about its center axis while the output shaft moves linearly, effectively separating the constraints: the short distance prevents rattle through the bearing's self-aligning capability, while the bearing's rotation enables sufficient moving range without increasing the worm-to-shaft distance.
2Manufacturing precision
If a conventional bearing mechanism is used without self-aligning capability, then the structure is simpler, but misalignment occurs during output shaft movement affecting precision
Solution Approach 1:
The self-aligning bearing mechanism is designed to automatically adjust and maintain proper alignment through its inherent rotational capability. The bearing rotates about its center axis in response to misalignment forces, self-correcting the alignment without requiring external adjustment mechanisms or complex control systems, thus achieving high precision while keeping the structure relatively simple.
3Reliability
If the second worm is positioned far from the output shaft to reduce force transmission, then rattle is reduced, but the actuator size increases
Solution Approach 1:
The patent merges the bearing support function with the alignment adjustment function into a single self-aligning bearing mechanism. This integration allows the second worm to be positioned close to the output shaft (reducing actuator size) while the bearing's self-aligning capability prevents rattle, effectively combining space efficiency with reliability in one component.
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 configuration effectively eliminates rattle, enhances the operational stability and accuracy of the lamp unit by ensuring precise alignment and movement, thereby improving the overall performance of the vehicle headlight in adjusting light beam direction.
Implementation Method 1
a second worm extending along a face perpendicular to the output shaft, a moving mechanism configured to be meshed with the second worm to move the output shaft in a direction orthogonal to the rotation axis
Implementation Method 2
the moving mechanism has a helical gear rack formed on face opposed to the second worm in the output unit, the helical gear rack configured to be meshed with the second worm
Implementation Method 3
a rotating mechanism configured to be meshed with the first worm to rotate the output shaft about a predetermined rotation axis
Data Source
AI summary
An actuator includes: an output unit 30 having an output shaft 33; and a first worm 40 and a second worm 50 extending along a face perpendicular to the output shaft 33, wherein: the output unit 30 includes a rotating mechanism 34a configured to be meshed with the first worm 40 to rotate the output shaft 33 about a predetermined rotation axis 33a, and a moving mechanism 39 configured to be meshed with the second worm 50 to move the output shaft 33 in a direction orthogonal to the rotation axis 33a; the first worm 40 and the second worm 50 are placed to sandwich the output shaft 33; and a distance between the second worm 50 and the output shaft 33 is shorter than a distance between the first worm 40 and the output shaft 33.