Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of adjustment of headlamp assembly in vehicles. In particular, the present disclosure relates to a gearless mechanism for manual aiming of the headlamp in horizontal and vertical aiming axis, in a vehicle.

BACKGROUND
[0002] Conventionally, headlamps in automobiles were using seal beam arrangements wherein the high and low beam were having separate components. But modern automobile uses composite headlamps employing single housing which contain both the high beam and low beams. The headlamps in the automobiles must be adjusted during initial assembly and during service life as vibrations occurring while driving the vehicle disturbed the standard alignment and their beam is misaligned.
[0003] Headlamp manual aiming operation is performed in vehicle assembly line to adjust low beam cut off vertically and horizontally and or high beam aiming. Mostly the Bevel gears mechanism or screw mechanism for activation of the vertical and horizontal aiming components is used. But these mechanisms have drawbacks of less or comparatively no access for aiming screws, high cost driven components and loss of power transmission with Bevel concept due to friction caused by sliding between tooth surface and load applied on the Bevel.
[0004] Efforts have been made in the art to address the issues to meet the above drawbacks. For example, Patent Document JP1995192505 discloses aiming mechanism of headlamp for automobile includes a nut member and with an aiming screw which is joined to the nut by screwing and projected forward and at the same time, following to the rotation of the nut member, which diagonally moves the diagonally moving parts joined with its front end part. A Bevel gear which is coupled to the teeth of a driver set in the direction rectangular to the aiming screw is installed in the nut member. And at the same time the nut member is elastically supported in the axial direction to release the joining by the nut member locking means by the thrusting force generated at the time of rotating operation of the nut member and thus smooth rotating movement of the nut member is made possible for headlight aiming.
[0005] While the referred patent document discloses gear mechanism for aiming of the headlamp of an automobile, there is a possibility of providing an improved and more efficient solution to the above stated problem without using gear mechanism.
[0006] There is, therefore, a need to provide a simple, easy, and cost-effective solution that can provide gearless mechanism manual aiming of the headlamp in horizontal and vertical aiming axis through an internal mounting means and external mounting means.

OBJECTS OF THE INVENTION
[0007] A general object of the present disclosure is to provide a mechanism for headlamp aiming without gear mechanism.
[0008] An object of the present disclosure is to provide a simple, easy, and cost-effective solution with fewer components that can provide aiming in horizontal and vertical aiming axis of the headlamp.
[0009] An object of the present disclosure is to provide a mechanism for the aiming of the headlamp in an internal mounting means and an external mounting means without impacting the functionality.
[0010] An object of the present disclosure is to provide a mechanism eliminating power loss by using a flexible elbow unit between 90° to 180° angles.

SUMMARY
[0011] Aspects of the present disclosure relate to the field of adjustment of headlamp assembly in vehicles. In particular, the present disclosure relates to a gearless mechanism for manual aiming of the headlamp in horizontal and vertical aiming axis, in a vehicle.
[0012] In an aspect, the proposed mechanism for headlamp aiming in a vehicle include a module housing that can includes a driving shaft, a driven shaft, an aiming knob, and a aiming pivot; a headlamp housing; and an elbow mechanism that includes a pair of arms hingedly coupled together at one end of the elbow mechanism where a first arm of the elbow mechanism is linked to the driving shaft and second arm to the driven shaft such that the rotation of the driving shaft initiated by manual rotation of the aiming knob is disposed to screw/unscrew a guide rib in the aiming pivot which travels along a slot and prevents the aiming pivot from rotation to enable a translation movement of the aiming pivot facilitated by the elbow mechanism for headlamp module in horizontal and vertical axis aiming.
[0013] In an embodiment, the pair of arms of the elbow mechanism linked to the driving shaft and the driven shaft forming a Hobson’s coupling for transmission of motion from the driving shaft to the driven shaft.
[0014] In an embodiment, the aiming of the headlamp module is performed through the orientation between the first arm and the second arm of the elbow mechanism at different angles varying from 90° to 180° angle without change in input force.
[0015] In an embodiment, the aiming pivot is a multi-cross section structure with a guide rib in the middle, and configured with threads at one end and a ball structure at the other end forming a push/pull means for low-beam lamp of the headlamp housing, depending upon unscrew/screw action of the guiding rib.
[0016] In an embodiment, the screw and unscrew movement of the multi-cross section structure is facilitated by the guiding rib to travel along the slot.
[0017] In an embodiment, the aiming knob is inserted into the module housing located in a key-way slot.
[0018] In an embodiment, to retain the aiming knob in place, a clinch washer is attached to the aiming knob internally from the module housing.
[0019] In an embodiment, the module housing and the headlamp module are coupled to each other for headlamp aiming in an external mounting means and an internal mounting means.
[0020] In an embodiment, the external mounting means of the module housing and the headlamp module is obtained through a bayonet mounting and an external screw driver is used to rotate the driving shaft for aiming.
[0021] In an embodiment, the internal mounting means of the module housing and the headlamp module is obtained by screw boss and locator.
[0022] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0024] FIG. 1 illustrates an exemplary cross-sectional side view of the gearless aiming mechanism using an internal mounting mode, in accordance with embodiments of the present disclosure.
[0025] FIG. 2 illustrates an exemplary cross-sectional side view of the gearless aiming mechanism using an external mounting mode, in accordance with embodiments of the present disclosure.
[0026] FIG. 3A illustrates application of elbow mechanism for 90° position between one arm and another arm, in accordance with embodiments of the present disclosure.
[0027] FIG. 3B illustrates application of elbow mechanism for 135° position between the one arm and another arm, in accordance with embodiments of the present disclosure.
[0028] FIG. 3C illustrates application of elbow mechanism for 180° position between the one arm and another arm, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION
[0029] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0030] Embodiments explained herein relate to the field of adjustment of headlamp assembly in vehicles. In particular, the present disclosure relates to a gearless mechanism for manual aiming of the headlamp in horizontal and vertical aiming axis, in a vehicle.
[0031] In an embodiment, the disclosed gearless aiming mechanism includes module housing; headlamp housing, and an elbow mechanism. The module housing can includes a driving shaft, a driven shaft, an aiming knob, an aiming pivot, and an elbow mechanism. The elbow mechanism includes a pair of arms hingedly coupled together at one end forming a Hobson’s coupling for transmission of motion from the driving shaft to the driven shaft such that the rotation of the driving shaft is disposed to screw/unscrew a guide rib in the aiming pivot which travels along a slot and prevents the aiming pivot from rotation to enable a translation movement of the aiming pivot facilitated by the elbow mechanism for headlamp module in horizontal and vertical axis aiming. The module housing and the headlamp module can be coupled for headlamp aiming in an external and an internal mounting means.
[0032] Referring now to FIG. 1 where an exemplary cross-sectional side view of the gearless aiming mechanism 100 using an internal mounting mode is shown. The aiming mechanism 100 includes a module housing 200; a headlamp housing 300, and an elbow mechanism 400.
[0033] In an embodiment, the module housing 200 can includes a driving shaft 202, a driven shaft 204, an aiming knob 206, an aiming pivot 208, and an elbow mechanism. The aiming pivot 208 is a multi-cross section structure with a guide rib 210 in the middle and configured with threads 214 at one end and a ball structure 216 at the other end forming a push/pull means for low-beam lamp of the headlamp housing 300 depending upon unscrew/screw action of the guiding rib 210. The screw and unscrew movement of the multi-cross section structure is facilitated by the guiding rib 210 to travel along the slot 212.
[0034] In an embodiment, the aiming knob 206 is inserted into the module housing 200 and located in a key-way slot 218 and to retain the aiming knob 206 in place, a clinch washer 220 is attached to the aiming knob 206 internally from the headlamp housing 300.
[0035] In an embodiment, the elbow mechanism 400 includes a pair of arms 402 hingedly coupled together at one end 404 of the elbow mechanism 400 where a first arm 402-1 of the elbow mechanism 400 is linked to the driving shaft 202 and second arm 402-2 to the driven shaft 204.
[0036] In an embodiment, the pair of arms 402 of the elbow mechanism 400 linked to the driving shaft 202 and the driven shaft 204 forming a Hobson’s coupling for transmission of motion from the driving shaft 202 to the driven shaft 204. The Hobson’s coupling demonstrates an efficient gearless transmission of power at right angle from the driving end to the driven end without any teeth matching and gear mechanism.
[0037] In an embodiment, the module housing 200 and the headlamp module 300 are coupled to each other for headlamp aiming in an external mounting means and an internal mounting means. In the internal mounting means of the module housing 200 and the headlamp module 300 is obtained by screw boss and locator. The screw boss and locator procedure provides a mean to produce linear motion by the rotation of the screw in the module housing 200.
[0038] In an embodiment, the driving shaft 202 and the driven shaft 204 is linked by elbow mechanism 400. The aiming pivot which is a multi-cross section structure with a guide rib 210 in the middle. The structure having threads 214 at one end for screw/unscrew motion and a ball-shaped structure 216 at other end.
[0039] In an embodiment, the module housing 200 and the headlamp housing 300 are rigidly mounted on the vehicle for pivotal movement about a horizontal axis and a vertical axis such that the pivotal movement will take place only in one axis at a time. The mounting of the module housing 200 and the headlamp housing 300 is performed in external mounting for manual head lamp aiming; the driving shaft 202 will be directly controlled by an external screw driver. The aiming pivot 208 tends to screw/unscrew based on the direction of rotation of the screw driver. The screw/unscrew behaviour is facilitated by the guiding rib 210 in the aiming pivot which moves through the slot 212 in the module housing 200. This prevents the aiming pivot 208 from rotation beyond the rib of the guiding rib 210 and enables a translation movement of the aiming pivot 208.
[0040] In an embodiment, the rotational input initiated by the aiming knob 206 and generation of transverse movement in the aiming pivot 208 through the elbow mechanism 400 is used for horizontal and vertical aiming in the headlamp manual aiming. The transmission movement in manual aiming in the proposed disclosure is achieved through two arms 402-1 and 402-2 of the elbow mechanism 400 coupled between the driving shaft 202 and the driven shaft 204. The linkage of two arms 402-1 and 402-2 creates a kinematic system that allows transmission movement at any required angles from 90° to 180° angle without change in input force.
[0041] FIG. 2 illustrates an exemplary cross-sectional side view of the gearless aiming mechanism 100 using an external mounting mode.
[0042] In an embodiment, the module housing 200 and the headlamp module 300 are coupled to each other for headlamp aiming in an external mounting means and an internal mounting means. In the external mounting means of the module housing 200 and the headlamp module 300 is obtained through a bayonet mounting and an external screw driver is used to rotate manually the driving shaft 202 for aiming.
[0043] In an embodiment, the rotation of the aiming knob 206 solves the dual purpose of the horizontal aiming and the vertical aiming and controlled at single point of axis.
[0044] In an embodiment, a module gasket 222 is used while coupling the module housing 200 and the headlamp housing 300 to prevent dust and water.
[0045] FIGs. 3A, 3B, and 3C illustrate application of elbow mechanism 400 for 90° position, 135° position, and 180° position between a first arm 402-1 and a second arm 402-2. The two arms 402-1 and 402-2 are coupled together at one end making a hinge joint 404. The key concept involved in the proposed manual aiming is the elbow mechanism 400, where the pair of arms 402 linked to the driving shaft 202 and the driven shaft 204 forming a Hobson’s joint for transmission of motion from the driving shaft 202 to the driven shaft 204. The Hobson’s coupling performs efficient gearless transmission of power at right angle from the driving end to the driven end without any teeth matching and gear mechanism.
[0046] In an embodiment, the elbow mechanism 400 creates a kinematic system that allows for efficient power/motion transmission at any required angles from 90° to 180° between the driving shaft 202 and the driven shaft 204.
[0047] In an embodiment, the elbow mechanism 400 activates the aiming component when the aiming knob 208 is rotated to transmit rotation of the driving shaft 202 to the driven shaft 204 and to aiming pivot 208. The transverse movement helps to move the low-beam cut-off and/or high beam of the headlamp module 300 with respect to horizontal axis. By using the elbow mechanism 400, the power loss is eliminated as there is no gear mechanism is involved. The FIG. 3A of the elbow mechanism 400 shows such a position with 90°. Whereas FIG. 3B shows a position with 135°, and the FIG. 3C at 180° angle.
[0048] Thus, the present disclosure provides gearless headlamp aiming mechanism 100 used of both horizontal aiming and vertical aiming through elbow mechanism 400. The power loss is eliminated as there is no tooth meshing involved and flexibility to orient the elbow unit at angle between 90° to 180° to enable access for aiming without change in the input force to the output. In the absence of high cost driven components like bevel gears, the proposed invention proved to be cost-effective.
[0049] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0050] The present disclosure provides a mechanism for headlamp aiming without gear mechanism.
[0051] The present disclosure provides a simple, easy, and cost-effective solution with fewer components that can provide aiming in horizontal and vertical aiming axis of the headlamp.
[0052] The present disclosure provides a mechanism for the aiming of the headlamp in an internal mounting means and an external mounting means without impacting the functionality.
[0053] The present disclosure provides a mechanism eliminating power loss by using a flexible elbow unit between 90° to 180° angles.
, Claims:1. An aiming mechanism (100) for headlamp aiming in a vehicle, the mechanism (100) comprising:
a module housing (200) comprising a driving shaft (202), a driven shaft (204), an aiming knob (206), and a aiming pivot (208);
a headlamp housing (300);
an elbow mechanism (400) comprising a pair of arms (402) hingedly coupled together at one end (404) of the elbow mechanism (400), and wherein a first arm (402-1) of the elbow mechanism (400) is linked to the driving shaft (202) and a second arm (402-2) to the driven shaft (204):
wherein the rotation of the driving shaft (202) initiated by manual rotation of the aiming knob (206) is disposed to screw/unscrew a guide rib (210) in the aiming pivot (208) which travels along a slot (212) and prevents the aiming pivot (208) from rotation to enable a translation movement of the aiming pivot (208) facilitated by the elbow mechanism (400) for headlamp module (300) in horizontal and vertical axis aiming.
2. The aiming mechanism as claimed in claim 1, wherein the pair of arms (402) of the elbow mechanism (400) linked to the driving shaft (202) and the driven shaft (204) forming a Hobson’s coupling for transmission of motion from the driving shaft (202) to the driven shaft (204).
3. The aiming mechanism as claimed in claim 2, wherein the aiming of the headlamp module (300) is performed through the orientation between the first arm (402-1) and the second arm (402-2) of the elbow mechanism (400) at different angles varying from 90° to 180° angle without change in input force.
4. The aiming mechanism as claimed in claim 1, wherein the aiming pivot (208) is a multi-cross section structure with a guide rib (210) in the middle, and configured with threads (214) at one end and a ball structure (216) at the other end forming a push/pull means for low-beam lamp of the headlamp housing (300), depending upon unscrew/screw action of the guiding rib (210).
5. The aiming mechanism as claimed in claim 4, wherein the screw and unscrew movement of the multi-cross section structure is facilitated by the guiding rib (210) to travel along the slot (212).
6. The aiming mechanism as claimed in claim 1, wherein the aiming knob (206) is inserted into the module housing (200) located in a key-way slot (218).
7. The aiming mechanism as claimed in claim 6, wherein to retain the aiming knob (206) in place, a clinch washer (220) is attached to the aiming knob (206) internally in the module housing (200).
8. The aiming mechanism as claimed in claim 1, wherein the module housing (200) and the headlamp module (300) are coupled to each other for headlamp aiming in an external mounting means and an internal mounting means.
9. The aiming mechanism as claimed in claim 8, wherein the external mounting means of the module housing (200) and the headlamp module (300) is obtained through a bayonet mounting and an external screw driver is used to rotate the driving shaft (202) for aiming.
10. The aiming mechanism as claimed in claim 8, wherein the internal mounting means of the module housing (200) and the headlamp module (300) is obtained by screw boss and locator.