VEHICLE HEADLAMP MECHANICAL LEVELING ACTUATOR
Field of Invention
The present invention relates to an aiming and leveling unit for vehicle headlamps, comprising a mechanical actuator for aiming and leveling of beam from a vehicle headlamp and a switch used to aim the beam to desired level, which can be accessed from the drivers' seat.
Introduction
Vehicle headlamps contain prism reflectors and glass to emit light beams in the forward direction. The light sources are usually discharge bulbs though other sources may also be used. A leveling unit is essential to a vehicle since it avoids unnecessary glare into the vehicles coming from the opposite direction. It also facilitates beam aiming where there are differential loads in the vehicles leading shifting of the weight towards the back of the vehicle and hence lifting of the beam from its reference position. Leveling units perform the function of aiming the light beam to the desired level with the controls being close to the drivers' seat and can be controlled easily by the driver.
Beam leveling can also be achieved by some primitive manual means with no access to the driver. However, for precise control other methods as described below are used. Any beam switching device as well as a leveling unit needs an actuator device for control. Two types of actuators are known: mechanical actuators and electronic actuators. Electronic actuators require electricity to run, are dependent on electric circuit and relatively much more expensive than mechanical actuators. On the other hand, mechanical actuators do not require electricity, are 30% less expensive and can be used any type of vehicle whether it is of 12V or 24V. Mechanical actuators are also more robust and have fewer chances of failure than that of electronic leveling actuator.

Objective of the Invention
The primary objective of the present invention is to provide an aiming and leveling unit for vehicle headlamps that has a simple construction and is less expensive
Another objective of the invention is to provide a suitable mechanical actuator for aiming and leveling of beam from a vehicle headlamp
Further objective of the invention is to provide a switch used to aim the beam to appropriate level, which can be accessed from the drivers' seat
The objective of the invention is also to provide a method of aiming and leveling of the vehicle light beam for optimum illumination of the road
Summary of the Invention
Two embodiments of the headlamp leveling mechanical actuator are described: (i) Top mounting and (ii) Bottom mounting.
All the parts of the bottom mounting actuator are common to that of the top mounting
actuator except the shaft with lever. The lever shaft and stud of top mounting actuator are
not required for bottom mounting actuator due to the design change of the shaft and lever.
The invention is an aiming and leveling unit with a mechanical actuator, fitment and
switch for vehicle headlamps that can be controlled by the driver, comprising:
a body with a locking area to fit with the headlamp, and a back cover;
a track guide to control the lever and the shaft along with a stud in between them;
a coil spring placed in between body and shaft;
a pivot screw which is tightened with the shaft and contains at its rear a manual
adjustment in the form of a knob for initial aiming of the headlamp;
the pivot screw in turn has a ball head which fits into a pivot bush of the headlamp
reflector/headlamp unit;

a cable wire to connect the lever and the switch to be operated by the driver; rubber cover prevent dust & water entry.
Another embodiment of the invention comprising
a body with a locking area to fit with the headlamp, and a back cover;
a track guide to control the shaft with lever;
a coil spring placed in between body and shaft with lever;
a pivot screw which is tightened with the shaft with lever and contains at its rear a
manual adjustment in the form of a knob for initial aiming of the headlamp;
the pivot screw in turn has a ball head which fits into a pivot bush of the headlamp
reflector/headlamp unit;
a cable wire to connect the shaft with lever and the switch to be operated by the driver;
rubber cover prevent dust & water entry.
The method of aiming and leveling with the unit such that when switch is operated by the
driver from its '0' position (initial position) to position 1, 2 or 3, the lever will get pulled
through cable wires and thereby push the shaft and compress the coil spring in the
forward direction. The pivot screw which is assembled with the shaft will also move in
the forward direction resulting in tilting the reflector /headlamp unit vertically downward.
This in turn results in lowering down the optical axis of the headlamp light beam while
climbing on the hilly track or in the loaded / unloaded condition so as to properly
illuminate the road in front of the vehicle.
The actuator is designed in such a way that if cable wire breaks, the head lamp will not
fall from the vehicle but remain at the initial leveling position.
Brief description of the drawings
Figures A and B show the fitment & function of the top mounting and bottom mounting headlamp leveling mechanical actuator, respectively, on the vehicle in unloaded condition.
Figures C, D and E show the function of headlamp leveling mechanical actuator on the vehicle at variable loaded condition.

Fig.l shows the assembly of mechanical headlamp leveling (top mounting) actuator
Fig.2 shows the sectional view of mechanical headlamp leveling (top mounting) actuator
Fig.3 shows the assembly with the headlamp, wire cable and switch at '0' position (top mounting)
Fig.4 shows the assembly with the headlamp, wire cable and switch at '1' position (top mounting)
Fig.5 shows the assembly with the headlamp, wire cable and switch at '2' position (top mounting)
Fig.6 shows the assembly with the headlamp, wire cable and switch at '3' position (top mounting)
Fig.7 shows the assembly of mechanical headlamp leveling (bottom mounting) actuator
Fig. 8 shows the sectional view of mechanical headlamp leveling (bottom mounting) actuator
Fig.9 shows the assembly with the headlamp, wire cable and switch at '0' position (bottom mounting)
Fig. 10 shows the assembly with the headlamp, wire cable and switch at '1' position (bottom mounting)
Fig. 11 shows the assembly with the headlamp, wire cable and switch at '2' position (bottom mounting)

Fig. 12 shows the assembly with the headlamp, wire cable and switch at '3' position (bottom mounting)
Detailed description of the invention
Detailed parts with their work function are as follows:-
The body (1) has locking area to fit with the head lamp,which is similar to electronic
actuator and has guide to travel the lever (3) which is assembled with shaft (2) with the
help of stud (11).
A coil spring (10) is placed in between the body and shaft. A Pivot screw (6) is tightened
with shaft. A knob (5) is fixed by press fitment at the back of pivot screw which is given
for manual adjustment for initial aiming of the head lamp.
The back cover (4) is tightened on the body with the help of B.T. screw (9). Pivot screw
is fitted with a ball head which fits into the pivot bush (14) of the headlamp to hold the
headlamp reflector or headlamp unit as shown in Fig. 3. The lever (3) is connected to
switch (12) through cable wire (17). Switch (12) and cable wire (17) are fitted on the
vehicle and will be operated by the driver through switch (12). A rubber cover (15) is
provided to prevent dust & water entry.
The aiming and leveling unit of the present invention comprises a mechanical actuator connected via a cable wire to a switch device that can be used to aim the light beam of the vehicle headlamp at the desired level. The switch device allows the leveling of the beam at certain fixed positions or may also be rotated smoothly wherein the light beam can be fixed at any level. This switch may be a manual device which is located near the driver's seat and can be easily controlled by the driver. The present invention has two embodiments involving the mechanical actuators, one for top mounting and other for bottom mounting depending on the vehicle headlamp design for the reflectors and discharge bulbs. The present mechanical leveling actuator is designed in such a way that it may replace electronic leveling actuator without having to make any changes in fitment dimensions of headlamp. Mechanical leveling actuator is operated and controlled by a manual driving switch near to driver via cable wires attached to actuator.

In the present invention, the mechanical actuator is fitted to head lamp reflector or the lamp as whole (i.e., as required by headlamp design) which pushes in linear direction and enables tilting of the reflector vertically. The required adjustment is controlled by a manual mechanical driving switch near the driver by means of a flexible attached to the mechanical actuator. This actuator can be used under loaded and unloaded vehicle conditions and the light beam leveling achieved accordingly in both conditions. Usually the switch contains four positions, the '0' or reference position, '1' position, '2' position and '3' position, wherein in the unloaded condition, the '0' position is the normal position and in the other positions, the light beam tilts downward. On the failure of system i.e. if cable breaks, it will remain always at '0' aiming position also have the facility of manual adjustment with the help of a knob provided to the back of actuator. The present invention has two embodiments. The bottom mounting unit is different from the top mounting in that the shaft, lever and stud of top mounting actuator is replaced by shaft with lever for the bottom mounting actuator.
A. Mechanical Head Lamp leveling actuator -Top mounting
The top mounting mechanical headlamp leveling actuator is comprised of moulded parts
of PA-6, m/c parts - screw, nut, washer etc. of MS and EN-1A, rubber moulded parts -
EPDM, coil spring of spring steel EN etc.
The top mounting mechanical actuator comprises the following main parts:
l.Body
2. Shaft
3. Lever
4. Back cover
5. Knob
6. Pivot screw
7. BT screw
8. Coil spring
9. Stud

10. O ring
11. Rubber cover

This is applicable to the top side fitment to the headlamp assembly when the fixed and horizontal adjustment screws are at the bottom side of the head lamp reflector. In this case, actuator lever is pulled back by a cable operated switch which pushes the shaft of actuator fitted to reflector or headlamp unit in forward direction which enables the headlamp beam level vertically downward position
Fitment and functioning of the top mounting mechanical headlamp leveling actuator
Fig. 1 shows the complete assembly of the Head Lamp Leveling Mechanical Actuator and fig. 2 shows the detailed section view. It consist of Nylon-6 molded parts i.e. Body (1), Shaft (2), Lever (3), Back cover (4), Knob (5).
The Body (1) has a locking area (7) to fit with the headlamp housing or bracket. Body (1) has a track (8) to travel the shaft (2) in between the body (1) and the back cover (4).
Shaft (2) has a guide hole to hold the pivot screw (6) which is made of EN-1A material and trivalent surface treatment, shaft (2) also has the provision to guide the lever (3). Knob (5) is press fitted at the back of pivot screw (6) which is given for manual adjustment.
Pivot screw (6) can be manually adjusted 6-8 mm in forward and backward direction by rotating the knob for the initial leveling of the headlamp.
Lever (3) is fitted with the body (1) with the help of stud (11) and coil spring (10) which is made of spring steel wire is assembled with shaft (2) and in between body (1).
Coil spring (10) compresses when lever (3) is pulled through cable wire (19) then shaft (2) moves in the forward direction, as the pivot screw (6) fitted to head lamp reflector

assembled with shaft (2) also moves in the forward direction which will result the lowering down the head lamp axis vertically.
The Lever (3) has a guide hole to accommodate the cable wire.
The back cover (4) is tightened on the back of the body (1) with the B.T. Screws (9) and
also has a provision for clamping to hold the wire cable (17).
0 ring (13) is made of EPDM rubber, which is assembled below the locking area (7) of
the body (1) to provide cushioning and the proper fitment with the headlamp.
The shaft contains two embosses to guide the lever and shaft OD to prevent the coil
spring from falling. The lever has a U type profile to accommodate the shaft embosses.
The body, shaft and lever are housed together and locked by back cover with the help of
screws.
B. Mechanical Head Lamp leveling actuator- Bottom mounting
The bottom mounting mechanical Head Lamp leveling actuator is comprised of moulded parts of PA-6 m/c parts - screw, nut, washer etc. of MS and EN-1A, rubber molded parts - EPDM, coil spring of spring steel EN etc.
All the parts of the bottom mounting actuator are common as of the parts of the top
mounting actuator except shaft with lever. Lever shaft and stud of top mounting actuator
are not required for bottom mounting actuator due to the design change of the shaft and
lever.
This is applicable to the bottom side fitment to the headlamp when the fixed and
horizontal adjustment screws are at the top side of the reflector or headlamp unit. In this
case, the shaft lever directly pulls the reflector / headlamp unit in backward direction
which enables the headlamp beam level vertically downward position.
Leveling / aiming function for 1, 2, 3 position is same with respect to existing. The
fitment to head lamp and to reflector bush of pivot screw ball is same as existing.

Fig. 7 shows the complete assembly of the Head Lamp Leveling Mechanical Actuator-bottom mounting and fig. 8 shows detailed section view. It consist of Nylon-6 molded parts i.e. Body (1), Shaft with lever (16), Back cover (4), Knob (5).
The body has a locking area (7) to fit with the head lamp housing or bracket. Body has a track (8) to travel the shaft with lever (16) in between the body (1) and the back cover (4).
Shaft with lever (16) has a guide hole to hold the pivot screw (6) which is made of EN-1A material and trivalent surface treatment. Shaft with lever (16) also has the provision to clamp and hold the wire cable (17). Knob (5) press fitted at the back of pivot screw (6) which is given for manual adjustment.
Pivot screw (6) can be manually adjusted 6-8 mm in forward and backward direction by rotating the knob for the initial leveling of the headlamp.
Coil spring (10) which is made of spring steel wire is assembled in between shaft with lever (16) and body (1).
Coil spring (10) compresses when shaft with lever (16) is pulled through cable wire (17) then shaft with lever (16) moves in the backward direction, and as the pivot screw (6) is assembled with shaft with lever (16), it also moves in the backward direction which will result the lowering down the headlamp axis.
The back cover (4) is tightening on the back of the body (1) with the B.T. Screws (9) and back cover (4) has a provision to hold the wire cable (17).
O ring (13) is made of EPDM rubber, which is assembled below the locking area (7) of the body (1) to provide cushioning and the proper fitment with the headlamp.

The shaft here contains both a through hole to accommodate the pivot screw as well as a
guide hole to accommodate and hold the cable wire. The coil spring is prevented from
falling by means of a shaft OD.
The body and shaft with lever are assembled together and locked by the back cover with
the help of screws.
In case of both embodiments, failure of mechanical actuator i.e. in case, the cable breaks,
the actuator / headlamp will remain at its '0' aiming position.
Advantages of the present invention
While the performance level of the mechanical actuator is same as that of electronic
actuators, its cost is significantly lower.
This actuator can be positioned in place of electronic actuator without any changes in the
vehicle design and at no extra cost.
The mechanical actuator has a longer life as water ingress, dust etc. do not affect as much
as in case of electronic leveling actuator.
Existing electrical leveling actuators of 12V can be used in 12V circuit vehicles whereas
24V actuators can be used in 24V electrical circuit vehicles only. Mechanical actuators
can be used any vehicle whether it is 12V or 24V. Mechanical actuators can operate
without battery.
In case of failure of the system, existing electrical actuators remain at the same position,
and cannot be adjusted whereas, mechanical actuators always remains in '0' aiming
position with the help of the coil spring provided to actuator shaft.
It is also worth mention that the shorter spring length can reduce the compression load.
Similarly, tight fitment of the coil spring to shaft causes restricted movement due to too
much fractional load on the shaft.

We Claim:
1. An aiming and leveling unit with a mechanical actuator, fitment and switch for vehicle
headlamps which can be controlled by the driver, comprising:
a body with a locking area to fit with the headlamp, and a back cover;
a track guide to control the lever and the shaft along with a stud in between them;
a coil spring placed in between body and shaft;
a pivot screw which is tightened with the shaft and contains at its rear a manual
adjustment in the form of a knob for initial aiming of the headlamp;
the pivot screw in turn has a ball head which fits into a pivot bush of the headlamp and
headlamp reflector/headlamp unit;
a cable wire to connect the lever and the switch to be operated by the driver;
rubber cover prevent dust & water entry.
2. An aiming and leveling unit as claimed in claim 1, wherein the said lever has a guide hole to accommodate the cable wire.
3. An aiming and leveling unit as claimed in claim 1, wherein the said shaft has a guide hole to hold the pivot screw.
4. An aiming and leveling unit with a mechanical actuator, fitment and switch for vehicle headlamps which can be controlled by the driver, comprising:
a body with a locking area to fit with the headlamp, and a back cover;
a track guide to control the shaft with lever;
a coil spring placed in between body and shaft with lever;
a pivot screw which is tightened with the shaft with lever and contains at its rear a
manual adjustment in the form of a knob for initial aiming of the headlamp;
the pivot screw in turn has a ball head which fits into a pivot bush of the headlamp and
headlamp reflector/headlamp unit;
a cable wire to connect the shaft with lever and the switch to be operated by the driver;
rubber cover prevent dust & water entry.

5. An aiming and leveling unit as claimed in claim 4, wherein the said shaft with lever has a guide hole to accommodate the cable wire as well as a hole to hold the pivot screw.
6. A method of aiming and leveling headlamp axis for optimum illumination of the road comprising:
operating of the switch by the driver from its '0' position (initial position) to position 1, 2 or 3, whereby the lever is pulled through cable wires, pushing the shaft and compressing the coil spring in the forward direction and in turn moving the pivot screw in the forward direction resulting in tilting the reflector /headlamp unit vertically downward.
7. A method of aiming and leveling headlamp axis for optimum illumination of the road
comprising:
operating of the switch by the driver from its '0' position (initial position) to position 1, 2 or 3, whereby the shaft with lever is pulled through cable wires, compressing the coil spring in the forward direction and in turn moving the pivot screw in the forward direction resulting in tilting the reflector /headlamp unit vertically downward.
8. An aiming and leveling unit with a mechanical actuator, fitment and switch for vehicle headlamps as herein described with reference to the description and drawings.
9. A method of aiming and leveling headlamp axis for optimum illumination of the road as herein described with reference to the description and drawings.