Claims:1. An aiming system (100) for a headlamp comprising:
a first aiming member (10) comprising a substantially cylindrical structure (12) having a first end (12a) and a second end (12b), wherein the second end (12b) is configured to create a pivotable connection with an optical member of the headlamp; and
a second aiming member (20) configured to engage with the first aiming member (10) for adjusting the aiming system (100), wherein the second aiming member (20) comprises:
an elongated portion (22) comprising a primary end (22a) and a secondary end (22b), wherein the elongated portion (22) further comprises a internal tubular portion (24) extending from the secondary end (22b) towards the primary end (22a);
an adjustment portion (26) provided on said primary end (22a) of the elongated portion (22); and
characterized in that the elongated portion (22) and the adjustment portion (26) are formed as a monobloc part, wherein the first end (12a) of the first aiming member (10) is configured to be inserted in the internal tubular portion (24) to create an operational assembly, and wherein the adjustment portion (26) comprises at least one multi access head (28) configured to allow multi-directional access of the aiming system (100).

2. The aiming system (100) as claimed in claim 1, wherein the first aiming member (10) comprises external thread (14) on the cylindrical structure (12).

3. The aiming system (100) as claimed in claim 2 wherein the internal tubular portion (24) comprises internal threads (24a) configured to engage with the external threads (14) of the cylindrical structure (12).

4. The aiming system (100) as claimed in claim 1, wherein the multi access head (28) includes at least one gear system provided on the multi access head (28) and configured to engage with an external gear member.

5. The aiming system (100) as claimed in claim 1, wherein the multi access head (28) includes at least one screw head configured to engage with a screwdriver tip.

6. The aiming system (100) as claimed in claim 5, wherein the multi access head (28) includes at least one combination having at least one of hex socket, slotted socket, scrulox socket, Phillips socket or Pozidriv socket.

7. The aiming system (100) as claimed in any of the preceding claims, wherein the second aiming member is configured to be assembled on a housing of headlamp such that the elongated portion is inside the housing.

8. A headlamp for an automotive vehicle comprising:
a housing (40);
at least one light source arranged inside the housing (40) and configured to produce a light beam;
at least one optical member arranged in relation to the at least one light source inside the housing (40), wherein the at least one optical element is configured to disperse the light beam towards the outside of the headlamp; and
an aiming system (100) according to claim 1 to 7 arranged on the housing and creating an operational assembly with the at least one optical member, wherein the headlamp is configured to allow multi-directional access of the aiming system (100).
9. The headlamp as claimed in claim 8, wherein the optical member is a reflector configured to reflect the light beam towards the outside of the headlamp.
, Description:Technical field
[0001] The present invention relates to an aiming system for a vehicle headlamp, more particularly to an aiming system having multi access head for adjusting the optical axis of the headlamp.
Prior art
[0002] Headlamps are used in automobiles and the like, for lighting the path ahead. The light beams of these headlamps need to be oriented properly to provide adequate lighting to the driver of the automobile under various driving conditions and at the same time, when it is a light beam with an horizontal cut-off such a passing or low beam or a fog beam, avoid dazzling vehicles coming from opposite direction. Currently, headlamps are available with multiple optical modules. The optical modules are assembled to a housing of a headlamp by means of connection points, and the optical module is movable relative to the housing to correct the orientation, in particular vertically as well as in azimuth or horizontally.
[0003] Conventionally, to adjust the optical axis of the optical modules of the headlamps, various aiming system are provided. The aiming systems move or rotate the optical modules along the axis of rotation as per the requirements. To level the light beams produced by the optical modules, these aiming systems uses a bevel gear sub assembly system that transfer the rotational movements to linear movement. The aiming system used currently is parallel to the aiming axis, which requires special tools for accessing to adjustment. Whereas, for aiming system having a perpendicular access there is a need for a separate gear sub assembly to perform the optical axis adjustment.
[0004] The prior art and the conventional methods have various disadvantages as described earlier and there is a need for an aiming system which can overcome the above limitations and provide an effective system for optical axis adjustment.

Summary of the invention
[0005] An object of the present invention is to solve the disadvantages described above of known aiming systems of headlamps. In particular, it is the object of the present invention is to provide an aiming system with a multi access head that allows accessing the aiming system from multiple directions, thus, allowing the optical axis adjustment without the need for additional parts.
[0006] In an embodiment of the present invention, an aiming system for a headlamp comprises a first aiming member comprising a cylindrical structure having a first end and a second end. The second end is configured to create a pivotable connection with an optical member of the headlamp. The aiming system further comprises a second aiming member configured to engage with the first aiming member for adjusting the aiming system. The second aiming member comprises an elongated portion comprising a primary end and a secondary end. The elongated portion further comprises an internal tubular portion extending from the secondary end towards the primary end and an adjustment portion provided on said primary end of the elongated portion. Further, the elongated portion the adjustment portion are formed as a monobloc part. Monobloc parts are usually defined as a part that are made as a single integral unit that are manufactured by casting or similar processes. The first end of the first aiming member is configured to be inserted in the internal tubular portion to create an operational assembly. Further, the adjustment portion comprises at least one multi access head configured to allow multi-directional access of the aiming system. The aiming member allows a simple manufacturing and assembly of the aiming system in the headlamp. Further, the design allows a compact design of the aiming system that may be adaptable with different types of headlamp design. In addition, the design allows precise adjustment of the optical axis by reducing the transmission losses of the conventional aiming systems.
[0007] In an embodiment of the present invention, the first aiming member comprises external thread on the cylindrical structure.
[0008] In an embodiment of the present invention, the internal tubular portion comprises internal threads configured to engage with the external threads of the cylindrical structure. The arrangement allows translation of rotational movement into lateral movement thus allowing the optical axis adjustment.
[0009] In an embodiment of the present invention, the multi access head has at least one gear system provided on the multi access head and configured to engage with an external gear member. The multi access head enables the use of different tools for performing the optical axis adjustment, thus, providing design flexibility.
[0010] In an embodiment of the present invention, the multi access head includes at least one screw head configured to engage with a screwdriver tip.
[0011] In an embodiment of the present invention, the multi access head includes at least one combination having at least one of hex socket, slotted socket, scrulox socket, Phillips socket or Pozidriv socket. In an embodiment of the present invention, the second aiming member is assembled on a housing of headlamp such that the elongated portion is located inside the housing.
[0012] In an embodiment of the present invention, a headlamp for an automotive vehicle comprises a housing and at least one light source arranged inside the housing that is configured to emit a light bundle and at least one optical member arranged in relation to the at least one light source inside the housing. The at least one optical element is configured to propagate the light bundle towards the outside of the headlamp and generate a regulatory light beam. The headlamp further comprises an aiming system according to claimed invention that is arranged on the housing and creating an operational assembly with the at least one optical member, wherein the headlamp is configured to allow multi-directional access of the aiming system.
[0013] In an embodiment of the present invention, the optical member is a reflector configured to reflect the light bundle towards the outside of the headlamp.

Brief Description of the figures
[0014] To complete the description and to provide a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate an embodiment of the invention, which should not be construed as restricting the scope of the invention, but only as an example of how the invention can be carried out. The drawings comprise the following characteristics.
[0015] Fig. 1 shows an isometric view of an aiming system for a headlamp, according to an embodiment of the present invention.
[0016] Fig. 2 shows a lateral view of the aiming system of Fig. 1, according to an embodiment of the present invention.
[0017] Fig. 3 shows schematic view of the aiming system of Fig. 1 showing the arrangement of various parts, according to an embodiment of the present invention.
[0018] Fig 4 shows a top view of a multi access head of the aiming system, according to an embodiment of the present invention.
[0019] The features, variants and different embodiments of the invention can be associated with one another, in various combinations, provided that they are not incompatible or mutually exclusive. In particular, variants of the invention can be envisaged that comprise only a selection of the features described below in isolation from the other features described, if this selection of features is sufficient to provide a technical advantage or to distinguish the invention from the prior art.
[0020] In particular, all of the variants and all of the embodiments described can be combined with each other if there is no technical reason preventing this combination. In the figures, elements common to a number of figures keep the same reference sign.

Detailed description of the invention
[0021] Hereinafter, embodiments of the present invention will below be explained in details by ways of examples with reference to the accompanied drawings. Throughout the description, same or similar reference numerals represent same or similar parts. The following description of the embodiments with reference to the drawings is intended to explain the general inventive concept of the present application, instead of limiting to the present invention.
[0022] In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details.
[0023] Traditionally, headlamps of a vehicle are provided with optical axis adjustment system that are used to level the headlamp optical axis to produce an optimal light beam pattern. These optical axis adjustment systems are also known as aiming system or levelling systems, as they are provided to ensure the light beam produced by the headlamp is level with respect to the vehicle. There are various kinds of aiming systems such as manual aiming systems or electro-mechanical aiming systems. Fig. 1 and 2 shows an aiming system 100, according to an embodiment of the present invention. As shown in said Fig. 1, the aiming system 100 is arranged with respect to a housing 40 of the vehicle headlamp. As seen in Fig. 1 and 2, the aiming system 100 is arranged such that it is partially inside the headlamp housing 40 and partially outside the housing 40 to allow access from outside of the lamp. The partial arrangement of the aiming system is to enable an operator to adjust an optical member such as a reflector that is typically placed inside the headlamp housing from the outside of the housing.
[0024] In an embodiment of the present invention as shown in Fig. 3, the aiming system 100 for a headlamp comprises a first aiming member 10 comprising a cylindrical structure 12 having a first end 12a and a second end 12b. The second end 12b may be configured and designed such that it may create a pivotable connection with the optical member of the headlamp. The pivotable connection may enable the optical member to move in a relative pivot movement with respect to the second end 12b. Further, the optical member is configured to move laterally about said pivotable connection with the second end 12b. The connection at the above-indicated point sometimes is referred to as a floating connection point. Conventionally, the optical member further comprises a fixed connection point with respect to the housing. The fixed connection point does not allow any lateral movement of the optical member at this point but may allow relative rotation of the optical member. The optical member such as a reflector is tilted to adjust the optical axis. Typically, the adjustment or tilting happens with respect to floating connection point and the fixed connection point. The optical member moves in lateral direction across the floating connection point and rotates at the fixed connection. The above-indicated movement causes the optical element to tilt about the fixed connection point.
[0025] In an embodiment of the present invention, the first aiming member 10 is designed as an adjustment shaft that is having cylindrical structure 12. The shaft may be designed having a uniform cross section along its length; however, in some cases the shaft structure may have a slight conical profile or may have varying cross section across the length. One of the end of the first member 10 usually includes a ball joint or a spherical joint that is configured to mate with a socket that may be formed on the optical member. The above-discussed arrangement having a ball joint or a spherical joint creates a pivotable connection between the first aiming member 10 and the optical member. Further, the first aiming member 10 comprises external thread 14 on the cylindrical structure 12. The external threads may be provided on the portion of the first aiming member 10 that is away from the ball joint portion.
[0026] The aiming system 100 of the present invention further comprises a second aiming member 20 that may be configured to engage with the first aiming member 10 for adjusting the aiming system 100. The second aiming member 20 is usually an adjusting screw that may be used to adjust the aiming system and further adjust the optical axis of the headlamp. In an embodiment of the present invention, the second aiming member 20 comprises an elongated portion 22 comprising a primary end 22a and a secondary end 22b. As discussed earlier, a part of the aiming system 100 needs to be accessed from outside, for this purpose, usually the secondary end 22b is arranged such that it is inside the headlamp housing 40 and the primary end 22a is arranged such that it is outside the housing 40. Usually, the primary end 22a is configured to allow access to the second aiming member 20 and the secondary end 22b is provided opposite to the primary end 22a in a lateral direction. For said purpose, the housing 40 may be provided with a slot or a hole through which the second aiming member 20 may be assembled on the housing 40. To create a tight sealing between the components a bush or grommet may be used to assemble the second aiming member 20 on the housing 40.
[0027] In an embodiment of the present invention, the elongated portion 22 further comprises an internal tubular portion 24 that may extend from the secondary end 22b towards the primary end 22a. The internal tubular portion 24 may be a hollow section that is created along the longitudinal length of the second aiming member 20. The internal tubular section 24 is created such that there is an opening at the secondary end 22b that further extends towards the primary end 22a. Further, the internal tubular portion 24 may include internal threads 24a that may be configured to engage with the external threads 14 of the cylindrical structure 12. The internal threads 24a usually have a helical profile; however, other profiles of the internal thread can be envisioned. Further, the profile of the internal thread 24a and the external thread 14 are substantially same to enable proper meshing.
[0028] In addition, an adjustment portion 26 is provided on said primary end 22a of the elongated portion 22. The adjustment portion 26 is designed as the portion of the second aiming member 20 that is configured to be accessed by the operator to adjust the aiming system 100. In a preferred embodiment of the present invention, the elongated portion 22 and the adjustment portion 26 are formed as an integral part. Usually they are made of plastic or polymer based material and may be created using moulding process such as injection moulding. Alternatively, metal-based part can also be created using similar or other suitable manufacturing process such that elongated portion 22 and the adjustment portion 26 are formed as integral part. The integral part design allows ease of manufacture and further enables a compact design. Further, the first end 12a of the first aiming member 10 is configured to be inserted in the internal tubular portion 24 to create an operational assembly.
[0029] In an embodiment of the present invention, the adjustment portion 26 comprises at least one multi access head 28 configured to allow multi-directional access of the aiming system 100. As shown in Fig. 1 and Fig. 4, the multi access head 28 is configured to provide multiple accessibility allowing multiple possible access to the aiming system using various tools. This enables ease of operation and further enables the operator to access the aiming system using different tools. Further, this enables simple and effective adjustment of the aiming system to adjust the optical axis. Further, the design may allow a compatibility with different types of headlamp designs.
[0030] In an assembled state, the second aiming member 20 is assembled on the housing 40 by inserting the elongated portion 22 through a slot that may be provided on the housing 40. Further, a grommet or a bush may be provided in the slot to provide a proper sealed assembly. The assembly is made such that the elongated portion 22 is completely passed through the hole and is completely inside the housing 40; however, the adjustment portion 26 is present outside the housing 40. Additionally, the first aiming member 10 is assembled such that the first end 12a is assembled inside the internal tubular portion 24 of the second aiming member 20. The internal threads 24a and external threads 14 are configured to mesh with each other. Further, the second end 12b is connected to the optical member and is configured to create a pivotable connection. Thus, as discussed above and as can be seen from Fig. 1 – 3, except for the adjustable portion 26 the remaining parts of the aiming system 100 are arranged inside the housing 40.
[0031] Further as seen in Fig. 4 and in Fig. 1, the multi access head 28 includes various engagement means such as gear systems, screwdriver access and an Allen key access that allow access from multiple directions using different tools. This allows the aiming system 100 to have design flexibility allowing to be used in different headlamp designs with no or minimal modifications. In an embodiment of the present invention, multi access head 28 includes at least one gear system provided on the multi access head 28. The at least one gear system may be further configured to engage with an external gear for adjusting the optical axis of the optical module. The gear system may be a bevel gear (but other types of gear system can be envisioned) that may be provided on the multi access head 28. The gear system may be integrally formed with the multi access head 28 or may be provided separately. However, the gear system is provided such that the gear system does not rotate about the multi access head 28. Rather, it is designed so that the rotation of the gear system further rotates the multi access head and subsequently the second aiming member about its axis. An external tool having matching gear pair teeth or using a Philips type screwdriver may access the gear system arrangement.
[0032] In addition, the multi access head 28 includes at least one screw head that may be adjusted using screwdriver tip. In addition, the multi access head 28 further may include a hex socket, slotted socket, scrulox socket, Phillips socket and/ or Pozidriv socket. The multi access head 28 in this configuration includes screwdriver access in a direction that is perpendicular to screwing axis, in a direction that is collinear or parallel to screwing axis and/ or includes an Allen type driver that can be used in a direction that is collinear or parallel to screwing axis. The screwing axis is an axis along which the screw moves when it is operated using a tool. In context of the present invention, the screwing axis can be equated to the axis that passes along the lateral length of the second aiming member 20.
[0033] In an alternate embodiment, the multi access head 28 includes at least one gear system provided on the multi access head 28 and configured to engage with an external gear member. The multi access head 28 may be adjusted using an external tool having matching gear pair teeth or using a screwdriver. Alternatively, the multi access head 28 may include at least one screw head configured to engage with a screwdriver tip. The above indicated might be accessed by a screwdriver either in a direction perpendicular to screwing axis or parallel to the screwing access. Further, in another embodiment, the multi access head 28 includes at least one combination having at least one of hex socket, slotted socket, scrulox socket, Phillips socket or Pozidriv socket. The multi access head may be accessed using specialised tools adapted to be used for above indicated socket design.
[0034] According to an embodiment of the present invention, the multi access head 28 may include at least one combination having at least one of hex socket, slotted socket, scrulox socket, Phillips socket or Pozidriv socket. In an exemplary embodiment of the present invention as shown in Fig. 4, the multi access head 28 includes a combination of gear system 28a that can be accessed using an external tool 50 having gear tooth or by a screwdriver 52 (as seen in Fig. 1) through the access point 28c1, a hex socket 28b and a screwdriver access 28c. The above-indicated combination allows multiple tools to be used and allows access in multiple directions. As discussed earlier, the gear system 28a may include a bevel gear, a helical gear, spur gear or similar types of gears. Further, the screwdriver access 28c may include at least one screw head configured to engage with a screwdriver tip. The screw head may be designed to have different profiles as indicated above and may be configured to allow access to different types of screwdriver head. It is to be noted that the above indicated combination may be varied as per the requirements and for different types of aiming system 100 using the above indicated examples, further, it may be possible to design various types of multi access head 28 having substantially similar combination or different combination to allow multi tool access.
[0035] According to the embodiment of the present invention, the aiming system 100 may be accessed from outside using an external tool that engages with the multi access head 28. The tool is configured to rotate said multi access head 28 provided on the adjustment portion 26 of the second aiming member 20. The internal threads 24a of the second aiming member 20 are engaged with the external threads 14 of the first aiming member 10. Due to the said arrangement, when the external tool engages the adjustment portion 26 through the multi access head 28, the second aiming member 20 is rotated about its axis. Further, as the first aiming member 10 is engaged to said second aiming member 20 the motion is transferred to the first aiming member 10. Due to the arrangement of the threads, the rotational movement is translated into linear movement of the first aiming member, which is then transferred to the optical element for performing the optical axis adjustment.
[0036] The pitch of the internal threads 24a and external thread 14 are advantageously designed and formed based on the amount of movement to perform the precise adjustment of the optical member. Further, the pitch of the gear assembly and the screw profile may be designed and formed to enable precise movement of the second aiming member 20 with respect to the first aiming member 10. The number of turn of the multi access head 28 required to create a predefined amount of movement of the second aiming member 20 may be calculated based on the design of the reflector and the headlamp and may vary based on specific design. It should be noted that though the pitch and profile of the threads and the multi access head 28 is an important factor for performing the precise adjustment, however, they may vary according to the headlamp requirements and may not affect the functioning of the aiming system of the present invention.
[0037] In an embodiment of the present invention, a headlamp for an automotive vehicle comprises a housing, at least one light source that is arranged inside the housing and configured to produce a light bundle. The at least one light source can be a halogen based light source, a LED light source that may be arranged in a matrix arrangement or as an single light source or may be a solid state light source. The light source may be configured to produce light bundles in cooperation with one optical element for performing various lighting functions such as high beam, low beam, cornering light functions etc. The headlamp further comprises at least one optical member arranged in relation to the at least one light source inside the housing. The at least one optical element is configured to propagate the light beam towards the outside of the headlamp. The optical member is designed to produce the desired lighting pattern that may be dispersed outside of the headlamp to generate said lighting functionalities.
[0038] In addition, the headlamp comprises an aiming system that is arranged on the housing. The aiming system 100 creates an operational assembly with the at least one optical member and is configured to allow multi-directional access of the aiming system 100. The aiming system 100 of said headlamp may be designed according to the embodiments discussed above to allow adjusting the optical axis of the headlamp using multiple tools and further allow multi directional access for the same. The aiming system 100 may enable horizontal and vertical axis adjustment of the headlamp axis. According to the embodiment, the optical member may be a reflector that is configured to reflect the light beam towards the outside of the headlamp. The reflector may be a direct reflector or an indirect reflector that is configured to reflect the light towards the front of the headlamp. The headlamp may be designed to be used in automotive vehicles such as passenger cars, SUVs, transportation vehicle, goods carriers and off-road vehicles as well.
[0039] Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention.