FIELD OF INVENTION:
Headlamp leveler is equipment used in automotives to adjust the light beam of the head lamp in the required position to help the vehicle driver to view the road irrespective of the rear loading of the vehicle.
Head lamp levellers are used to adjust the angle of inclination of the head lamps according to the load conditions in the vehicle.
PRIOR ART:
Since 1998 the ECE-Regulation R48 requires the compensation of vehicle inclination caused by different loading conditions. The purpose of this regulation is on the one hand to avoid glaring of oncoming traffic and on the other hand to ensure an optimum range of illumination. For Halogen headlamps it is allowed to realize this vertical aim control (VAC) as manual controlled whereas for Xenon headlamps an automatic vertical aim control is require.
When the rear side of the vehicle is loaded (41) the light beam of the car tends to move upwards. To neutralize that effect leveling mechanism is used to focus the light beam in the required position. The headlamp is hinged with a pin to the headlamp housing and the shaft of head lamp leveler pushes the lamp backward and forward for adjustment. This is illustrated in Fig-1
In slanting roads the rear portion of the car gets the component of the car's weight. This shifts the position of light beam away from the required position and need to be adjusted to reposition the light beam on the required position (illustrated in fig-2).
There are two types of headlamp leveler according to OEM's fitment requirements.
1. Internal mounting type headlamp leveler - illustrated in Fig - 3.
2. External mounting type headlamp leveler - illustrated in Fig - 4.
External mounting type headlamp leveler is mounted outside the headlamp housing of the vehicle. These levelers are provided with features for initial Headlamp position adjustment.
Internal mounting type headlamp leveler is mounted inside the headlamp housing of the vehicle. There is no requirement for fully sealed actuator.
The existing construction of headlamp leveler allows the vehicle driver to choose the selector switch normally 2 or 3 positions to adjust the lamp position. The position sensing is possible by a linear or rotary potentiometer, which halts the motor in each position.
The manual vertical aim control is used with head lamp and more specifically with Halogen headlamps. The driver uses a rotary or slide switch to adjust the headlamps according to the tilt of the vehicle.
As per AIS 012.AIS 008 there is no specification for number of positions and linear displacement of shaft corresponding to the switch position. According to the driver convenience the Headlamp leveler gets operated.
In the case where a headlamp-leveling device is necessary to satisfy the requirements of C1.6.2.6.1.1 and 6.2.6.1.2, the device shall be automatic.
However, devices which are adjusted manually, either continuously or non- continuously shall be permitted, provided they have a stop position at which the lamps shall be returned to the initial inclination defined in c1.6.2.6.1.1 by means of the usual adjusting screws or similar means. These manually adjustable devices shall be operable from driver's seat.
Continually adjustable devices shall have reference marks indicating the loading conditions that require adjustment of dipped beam.
The number of positions on devices which are not continuously adjustable shall be such as to ensure compliance with the range of values prescribed in c1.6.2.6.1.2 in all the loading conditions defined in annex B.
AiS-008/2001
ANNEX :B
STATES OF LOADING TO BE TAKEN INTO CONSIDERATION IN
DETERMINING VARIATIONS IN THE VERTICAL ORIENTATION OF
THE DIFPED-BEAM HEADLAMPS
Loading conditions on axles referred to in CI. 6.2,6.1 and 6 J.6.3.lof this standard.
B1 For the following tests, the weight of the passengers shall be calculated cm die basis of 75 kg per person.
B2 Loading conditions for different types of vehicles:
B2.1 Vehicles in Category Ml:
B2.1.1 The angle of the light beam of the dipped-beam headlamps shall be determined under the following load conditions :
B2.1.1.1 one person in the driver1 s seat:
B2.1.1.2 the driver, plus one passenger in the front seat farthest from the driver;
B2.Ll.3ihe driver, one passenger in the front seat farthest from tbe driver, all the seats farthest to the rear occupied;
B2.1.1.4 all the seats occupied;
B2.1.1.5all the seats occupied, plus an evenly distributed load in the luggage boot, in order to obtain the permissible load the rear axle or the front axle if the boot is at the front If the vehicle has a front and a rear boot the additional load shall be appropriately distributed in order to obtain the permissible axle loads. However, if the maximum permissible laden weight is obtained before the permissible load on one of the axles, the loading of the boot(s) shall be limited to the figure which enables that weight to be reached;
B2.1.1.6 driver, phis an evenly distributed load in the boot, in order to obtain the permissible load on the corresponding axle. However, if the maximum permissible laden weight is obtained before the permissible load on the axle, the loading of the boot(s) shall be limited to tbe figure which enables that mass to be reached.
B2.1.2 In determining the above loading conditions, account shall be taken of any loading restrictions laid down by the manufacturer.
B2.2 Vehicles m Categories M2 and M3:
AIS- OGS ' 2001
Hie angle of the light beam from the dipped-beam headlamps shali be determined under the following loading conditions:
B2.2.1 vehicle unladen and one person in the driver's seat;
B2.2.2 vehicle is laden such that each axle cames its maximum technically permissible load or until the maximum permissible weight of the vehicle is attained by loading the front and rear axles proportionally to their maximum technically permissible load whichever occurs first.
B23 Vehicles m Category N with load surfaces:
B2.3 1 The angle of the light beam from the dipped-beam headlamps shall be determined under the following loading conditions;
B2.3.1.1 The vehicle unladen and one person in the driver s seat;
B2.3.1.2 Driver, plus a load so distributed as to give the maximum technically permissible load on the rear axle or axles, or the maximum permissible weight of the vehicle, occurs first, without exceeding a front axle load calculated as the sum of the front axle load of the unladen vehicle plus 25% of the maximum permissible pay load on the front axle. Conversely, the front axle is so considered when the load platform is at the front.
B2.4 Vehicles m Category N - without a load surface:
B2.4.1 Drawing vehicles for semi-trailers:
B2.4.I.1 unladen vehicle without a load on the coupling attachment and one person in the drivers seat
B2.4.1.2 one person in the driver's seat; technically permissible load on the coupling attachment in the position of the attachment corresponding to the highest load on the rear axle.
B2A2 Drawing vehicles for nailers:
B2.4.2.1 vehicle unladen and one person in the driver's seat;
B2.4.2.2 one person in the driver's seat, all the other places in die driving cabin being occupied
For these devices also, the loading conditions of annex B that require adjustment of the dipped-beam shall be clearly marked near the control of the device.
The vehicle Orientation (6.2.6.1.1, 6.2.6.1.2) is designed by the manufacturers. The initial downward inclination of the cut-off of the dipped-beam to be set in the unladen condition of the vehicle with one person in the driver's seat shall be specified within an accuracy of 0.1% by the manufacturer and indicated in a clearly legible and indelible manner on each vehicle close to either headlamps or the manufacture's plate by the symbol shown in Annex A (Figure 11 A). The value of this indicated downward inclination in C1.6.2.6.1.2.
The relationship between mounting height and vertical inclination percentage is illustrated in Fig - 11B. Depending on the mounting height in meters (h) of the lower edge of the apparent surface in the direction of the reference axis of the dipped- beam headlamp, measured on the unladen vehicle, the vertical inclination of the cut¬off of the dipped-beam shall, under all the static conditions of Annex B, remain between the following limits and the initial aiming shall have the following values
a. h< 1.0
Limits : between 0.5% and 2.5%
Initial aiming : between 1.0% and 1.5%
b. h >1.0
Limits : between 1.0% and 3.0%
Initial aiming : between 1.5% and 2.0%
At the discretion of the manufacturer, in cases where h is between 0.8 m and 1.0 m, the values specified for h > 1.0 m can be used. The application for the vehicle type- approval shall, in this case, contain information as to which of the two alternatives is to be used.
The dipper - beam inclination may be defined as follows:
First being as the angle expressed in milli-radians between the direction of the beam towards a characteristic point on the horizontal part of the cut-off in the luminous distribution of the headlamp and the horizontal plane.
The second option being by the tangent of the angle, expressed in percentage inclination, since the angles are small (for these small angles, 1% is equal to 10 mrad). If the inclination is expressed in percentage inclination, it may be calculated by means of the following formula: (hi^xlOO L
hi : is the height above the ground, in mm, of the above mentioned characteristic point, measured on a vertical screen perpendicular to the vehicle longitudinal median plane, placed at a horizontal distance L.
h2 : is the height above the ground, in mm, of the centre of reference (which is taken to be the nominal origin of the characteristic point chosen in hi)
L is the distance in mm from the screen to the centre of reference negative values denote downward inclination (see Figure 5). Positive values denote upward inclination.
This drawing represents a category M vehicle, but the principle shown apples to vehicle of other categories.
Where the vehicle does not incorporate a headlamp leveling system, the variation in dipped-beam inclination is identical with the variation in the inclination of the vehicle itself.
We describe herein the existing headlamp leveler which is illustrated in Fig - 6.
Some of the vehicles have manual head lamp levelling system today in which the driver has the possibility of adjusting the headlamp inclination specific to the loading conditions with a switch on the dashboard.
In the current construction of headlamp leveler, a motor (1) holds a pinion (12) in its output shaft drives a combination gear (13) and inturn drives a helical gear (3) to a calculated Speed. The helical gear (3) is fixed to the bottom housing by snap fit has a internal thread that drives the push rod (4). The lock push rod has a internal thread in which the headlamp leveler shaft (5) is screwed. Initial positioning of the lamp is set by adjusting the screw (5) with the bevel gear assembly (8) externally. The moving lock push rod also actuates a linear potentiometer fitted on to a PCB (6). The position sensing is done with this potentiometer. The assembly is covered with a top case (9) with seals to protect the system against water.
Fig - 7 illustrates the circuit of actuator which is described herein.
The actuator relies on feedback control for accurate positioning. The TLE4209 IC was specifically designed for automotive headlight beam control.
A three-pin connector provides electrical power and control. Two of them for supply power, and the third one gives the desired position(Reference Position) as DC voltage. The IC controls the motor , through the input obtained from IC's Error amplifier which gives the difference between Reference and Feedback Position , where then this output mechanically drives the shaft.
The IC's power section contains an H-bridge capable of driving 0.8 A, which is more than sufficient for the intended application.
The switch (21) having three positions marked 1,2,3 which is manually selectable gives the input to the PCB circuit (6) as reference voltage. Difference between the reference voltage and the current voltage is an input to the electric motor (1) in the mode of power supply with a specified time. The potentiometer resistance varies with respect to the displacement moved on lock push rod. This resistance input is given as a feedback voltage to the internal circuit which has pre-determined voltage reference for respective displacement values.
A comparator compares the feedback voltage and the reference voltage and controls the motor. When the difference between the reference voltage and the current voltage is zero the motor will stop.
The existing headlamp leveler have the following features:- 1 .Electronic type control torque
2. Transmitted by gear trains
3. Rotational movement converted to axial movement by thread mechanism
The switch controls the axial movement of the actuator and position of the output shaft. Depend s upon the load we can set the Headlamp leveler position. In existing type switch has three position in the order of quarter, half and full load conditions.
OBJECTS OF THE INVENTION:
The invention is aimed in achieving a step less headlamp leveler which may be categories under the category of Manual vertical aim control, which allows the driver to adjust the headlamps at required position according to his convenience. The headlamp leveler as per the invention uses only mechanical elements driven by a DC motor to move the shaft of the leveler to a same distance with the same speed as the existing levelers.
BRIEF DESCRIPTION OF THE INVENTION:
The Step less Headlamp leveler as envisaged in the invention is capable of using with both internal and external mounting type system. It is a Electro mechanical type actuator and manual operating type.
It is very compact and cost effective type actuator.
It has Electro Mechanical type control wherein the rotational movement is converted to axial movement by cam mechanism and further infinite positions can be attained, thereby resulting in a step less headlamp leveler.

The invention thereby achieves the first object of using a simple electromechanical means of control but resulting in overcoming the disadvantage suffered of selectable limited three positions of the switch.
The reference numerals marked in the
1 - Face cam
2 - Worm and worm wheel drive
3 - Motor
4 - Pinion
5 - Lock Push rod (follower)
6 - centre shaft
7 - shock Absorber
8 - Washer
9 - Top Plate
10 -Bottom Plate
11 - Radial Play Control Pin
12 - Connector seal
13 - Circular Terminal 3(top side)
14 - Circular Terminal 1
15 - Helical Gear
16 - Combination Gear
17 - Bellow
18 - Rubber seal
19 - Bottom case
20 - Gasket
21 - Top case
22 - Cork
23(a) - Angular terminal 1 23(b) - Angular terminal 2 23(c) - Angular terminal 3 24- Guide
figures annexed herein is given below:-
25(a) - Connector Terminal 1

25(b) - Connector Terminal 2 25(c) - Connector Terminal 3
26 - Circular Terminal 2
27 - Bypass Terminal
28 - Slider 29(a) -wire 1 29(b) - wire 2
30 - Terminal Block
31 - Adjuster
32- Gear
33- Rocker Arm
DESCRIPTION OF THE INVENTION WITH REFERENCE TO DRAWINGS:
The working principle of the invention is now described with reference to figure 12. A power supply is given to the motor, worm is press fitted to motor shaft. Due to motor shaft rotation, the worm drives the worm wheel. The worm wheel and cam is combined with center shaft. The worm wheel and cam is press fitted to center shaft to rotate at same place. To restrict the axial play of shaft the washer is added below the top plate. Lock push rod is located between top plate and bottom plate through hole. The radial movement of lock push rod is controlled by two pins called as radial play control pin.
Because of the cam rotation, lock push rod moves forward and reverse axially. To give the axial movement the cam is designed as a angular one and defined end circular face is flattened, to give smooth movement.
The motor assembly is located at bottom plate and center shaft is placed through hole between bottom and top plate.
The invention is illustrated in Fig - 9. The motor rotates in one direction continuously. The pushrod and the shaft move up and after reaching the full distance in one direction automatically reverse in the other direction. An indication may be provided to the driver for the maximum positions in the form of light or beep. The movement can be intermittently stopped in any position just by releasing the leveling switch.
Fig - 20A is top-view without top case and bottom case and Fig -20B is the cross- section view of completed assembly with the top case and the bottom case respectively.
The construction of the headlamp leveler as per the invention is described herein with Fig - 9. A face cam (1) is used along with a follower (5) to obtain the reciprocation movement of leveler. The face cam is driven by a DC motor (3) through a worm and worm wheel drive (2). The worm and worm wheel mechanism is used to obtain the required speed reduction. The cam follower (also called as push rod) holds a shaft (6) which is used to do initial adjustments of position of the lamp is guided in the headlamp leveler housing (not shown).
The advantages achieved in the invention is:-
The Headlamp leveling equipment has a stepless (infinite) position-adjusting feature and this can be achieved by electro mechanical means like face cam, cylindrical cam, rocker arms, and eccentric connecting rod mechanisms. However face cam and rocker arm have been selected as preferred embodiments to describe the invention.
When the invention is envisaged with a face cam then face cam is used to reciprocate the pusher rod along with its followers. This can even be done with one faced cam and the return motion through a spring or intermittent levers by positioning the cam in various angles.
In another second embodiment, the alternate mechanical arrangement, which is, also envisaged which is illustrated in Fig - 10 which uses the principle of rocker arm. The rocker arm (33) is made to oscillate by a pin provided in the gear (32), which in turn is driven by a dc motor (31). The rocker arm in turn moves the push rod (34) of leveler up and down. The novelty of the invention lies for using the rocker arm principle in headlamp leveler application.
A circular method of electrical control in the system to get plurality of positions is described with reference to Figure 13. The electrical control in the system to get number of positions.
The Terminal 1 and the Terminal 3 is placed 90 degree apart from each other. The Terminal 2 is placed between terminal 1 and 3 to give compact size. The Terminal 2 connected with topside Circular terminal, which is placed at the helical gear.
The power supply is given to the motor positive through the Terminal 1,3 and 2. Negative supply is directly given to motor.
When the power supply is given to the terminal 3, the motor gets activated. The helical gear rotates till terminal 3 is reached.
The plastic portion in helical gear. The circuit is open because there is no connection between terminal 3 and 2, since the Terminal 3 reaches the plastic portion.
To get the next position the power supply is given to Terminal 1. Helical gear rotates till the terminal 1 gets into the Plastic portion.
The plurality of positions, meaning infinite positions is illustrated in Figure 14, as per the circular method. The position 0,1 and 2 is shown in sequentially and positions 2 to 1 and 1 to 0 can be obtained also by same procedure.
The actual operation of the invention is now described herein with illustrations made in figure 15A and figure 15B. Further Figure 20C is the side view of Figure 15A without cases and Figure 20D is the cross-sectional view of Figure 15A at cam center.
The connector terminals are connected with angular terminal and a wire is used to combine motor with terminals. The circular terminal 1 and 2 are intermediately connected to circular terminal 3 (top side). To get the required position the plastic portion is placed between circular terminal 1 and 2.
The mechanism of operation is described herein.
The Cam is rotated due to helical gear and also gives the axial Movement by guide. Guide is firmly fixed with bottom case. (See figure 16).
The Lock push rod is snap fitted to cam and threaded by the Shaft. It is a intermediate component to transfer for torque and movement of cam to output shaft. To avoid radial play, lock push rod is guided at top case.
The principle of operation is described herein with Figure 16B.
The power supply is given to the motor by terminals. Gear train is activated by torque given by the motor. Helical gear is connected with cam with the use of key way. Motor stops when terminal 1 comes to contact with plastic. To go the further position terminal 3 is activated through switch action. The Terminal 1 and 3 is alternatively get powered to reach sequential positions.
Another method for obtaining position is a linear method for 0 to 2 positions is illustrated in Figure 17.
The power supply (+ Ve) is by passed to terminal 1 and 2. Terminal 3 is connected to motor (+ Ve). Motor negative is directly connected with power supply (- Ve). Terminals are intermediately connected by lock push rod.Lock push rod moves axially when motor rotates.
At position 0 , the terminal 1 and 3 is connected and terminal 2 is in open circuit. For position 0 to 1 , power supply is given to the terminal 1. The motor rotates till lock push rod reaches the plastic portion. Now motor get in to open circuit and stops. For position 1 to 2, power supply is given to the terminal 2 and lock push rod moves further forward till to plastic portion.
For reversing the position , polarity of power supply given to the terminals are reversed by switching action. For 2 to 1 , terminal 1 is activated. Terminal 1 and 2 are activated alternatively, to get the positions sequentially.
We now describe further the linear method for 0 to 3 positions with illustrations in Figure 18. Further Fig 21 is the view of complete assembly whereas Figure 18 is the terminal block electrical circuit drawing.
Terminal 1 and 2 is connected to power supply by switching action. Hatching portion in the terminals are insulated area. Terminal 3 is directly connected to motor (+ Ve). Terminal 1 and 2 is connected to terminal 3 through slider. At 0 position , terminal 1 and 3 is connected through slider. Slider lies in plastic portion of terminal 2.
For position 1 , power supply is given to terminal 1 and through slider the circuit is closed , the motor starts. Slider moves axially to and fro, when motors rotates. The circuit becomes open , when the slider reaches the plastic portion of the terminal 1 and the motor stops.
For position 2 , the power supply is switched to terminal 2. Till to plastic portion , slider transverse on the path and stops. For position 3 , the terminal 1 is charged by power supply.
For reverse position 3 to 2 , 2 to 1 and 1 to 0 , the polarity of power supply is reversed which is engaged with the terminals by switch actions.
The terminal block is now described in detail for better understanding of the invention with figure 19A, 19B and 19C.
The Black shaded portions are terminals, and it is connected in series The White portions are plastic portion (insulation portion)
A Continuous contact will be there at terminal set 3.
In the actuator the Slider has a contact with all the three terminals at any time. As per the invention, we consider 0 to 3 positions as 1 to 4 positions. 1 is rest position (at initial condition). If we want to move 1 to 2, the terminal set 1 will get power supply connection and it will stop at 2 (at plastic portion). For 2 to 3, terminal set 2 is connected with power supply and it will stop at 3. Like wise it will continue and return.
Pinion is press fitted with motor shaft and motor assembly is snap fitted at bottom case. Combination gear and helical gear are snap fitted at bottom case. Slider is insert molded with lock push rod. Terminals are insert molded with terminal block. Top case and bottom case is snap fitted.
Power supply is given to the motor through terminals . Pinion transmits the motor torque to combination gear. Combination gear has both spur gear and worm. Worm gives torque to helical gear. Helical gear and lock push rod is connected with thread mechanism . By thread mechanism , the rotary movement is converted to axial movement. Lock push rod and shaft moves together by thread which is placed at both shaft and lock push rod.
Due to the movement of lock push rod , slider also moves axially to and fro which has constant contact with terminal block. To get the various position , power connection is switched in between terminal 1 and 2. Terminal 3 is connected with terminal 1 and 2 through slider. Terminal 3 is divided in to two half. First half (top half-connector side) is directly connected to motor (+Ve) and the second half which has contact with slider is connected with motor (-Ve).
At position 0 the slider at touches plastic portion of terminal 2 and conductive portion in terminal 1. Power supply is given to the terminal through switch. For position 1, terminal 1 is charged by supply and motor starts to run.

WE CLAIM:
1. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a power supply means;
(b) a leveller switch;
(c) a DC motor operable by the leveller switch for receiving the power supply from power supply means;
(d) a CAM mechanism driven by the motor,
(e) a lock-push rod driven by the cam mechanism, characterized in that the rotary motion of the said motor is converted to axial movement of the said lock-push rod by said CAM mechanism; and
(f) a leveller shaft threaded on to the lock push rod for corresponding motion to guide the lamp position adjustment of the lamp in the housing.
2. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a power supply means;
(b) a leveller switch;
(c) a DC motor operable by the leveller switch for receiving the power supply from power supply means;
(d) a ROCKER ARM mechanism driven by the motor;
(e) a lock-push rod driven by the cam mechanism, characterized in that the rotary motion of the said motor is converted to axial movement of the said lock-push rod by said rocker arm mechanism; and
(f) a leveller shaft threaded on to the lock push rod for corresponding motion to guide the lamp position adjustment of the lamp in the housing.
3. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a power supply means;
(b) a leveller switch;
(c) a DC motor operable by the leveller switch for receiving the power supply from power supply means;
(d) a CAM mechanism driven by the motor;
(e) a lock-push rod driven by the cam mechanism, characterized in that the duration of rotary motion of the said motor is converted to corresponding axial movement of the said lock-push rod by said CAM mechanism; and
(f) a leveller shaft threaded on to the lock push rod for corresponding motion to guide the lamp position adjustment of the lamp in the housing.
4. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a power supply means;
(b) a leveller switch;
(c) a DC motor operable by the leveller switch for receiving the power supply from power supply means;
(d) a ROCKER ARM mechanism driven by the motor;
(e) a lock-push rod driven by the cam mechanism, characterized in that the duration of rotary motion of the said motor is converted to corresponding axial movement of the said lock-push rod by said rocker arm mechanism; and
(f) a leveller shaft threaded on to the lock push rod for corresponding motion to guide the lamp position adjustment of the lamp in the housing.
5. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a power supply means;
(b) a leveller switch;
(c) a DC motor operable by the leveller switch for receiving the power supply from power supply means;
(d) a CAM mechanism driven by the motor;
(e) a lock-push rod driven by the cam mechanism, characterized in that the amount of rotary motion of the said motor is converted to corresponding amount of axial movement of the said lock-push rod by said CAM mechanism; and
(f) a leveller shaft threaded on to the lock push rod for corresponding motion to guide the lamp position adjustment of the lamp in the housing.
6. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a power supply means;
(b) a leveller switch;
(c) a DC motor operable by the leveller switch for receiving the power supply from power supply means;
(d) a ROCKER ARM mechanism driven by the motor;
(e) a lock-push rod driven by the cam mechanism, characterized in that the amount of rotary motion of the said motor is converted to corresponding amount of axial movement of the said lock-push rod by said rocker arm mechanism; and
(f) a leveller shaft threaded on to the lock push rod for corresponding motion to guide the lamp position adjustment of the lamp in the housing.
7. An electromechanical Head Lamp leveller assembly as claimed in claims 1 to 6, is characterized in the leveller switch adapted for release such that the rotary motion of the motor is sustainable at any point of motion of motor to hold the lock- push rod at any position by positioning the leveller switch at the specific location thereby achieving infinite positions of operation of lock-push rod and thereof of the leveller switch.
8. An electromechanical Head Lamp leveller assembly as claimed in claims 1 to 6, is characterized in the leveller switch adapted for release such that the rotary motion of the motor is interruptable at any point of motion of motor by switching off the leveller switch at any point.
9. An electromechanical Head Lamp leveller assembly as claimed in claims 1, 3 and 5; is characterized in the configuration of the cam means adapted as an angular means with a flattened defined end circular face such that due to rotary motion of the motor in the single direction, the said push rod and thereby the leveller shaft move up to full distance in a single direction and automatically reverse in another direction.
10. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a top plate;
(b) a bottom plate;
(c) a motor mounted on the bottom plate;
(d) a power supply means connected to the motor;
(e) a centre shaft disposed between the top plate and the bottom plate;
(f) a worm press fitted to the motor shaft driven by the motor;
(g) a worm wheel driven by the worm thereby forming a helical gear, press fitted to the centre shaft and capable of making rotational movement with the centre shaft;
(h) a CAM press fitted to the centre shaft driven by the helical gear is capable of making rotational movement with the centre shaft;
(i) a lock push rod disposed adjacent to the centre shaft and between the top plate and the bottom plate and driven by the CAM, and further capable of making axial movement
(j) a leveller shaft driven by the lock push rod with thread mechanism, said shaft secured to the internal threads in the push rod, whereby the lock push rod and the leveller shaft move combinedly and correspondingly;
(k) a washer mounted below the top plate for arresting the axial play of central shaft;
(I) a pair of radial play control pin to arrest radial movement of the lock push rod,
such that the motor drives the CAM rotationally with the helical gear which CAM moves the lock push rod forward and backward axially.
11. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a top plate;
(b) a bottom plate;
(c) a motor mounted on the bottom plate;
(d) a power supply means connected to the motor;
(e) a centre shaft disposed between the top plate and the bottom plate;
(f) a worm press fitted to the motor shaft driven by the motor;
(g) a worm wheel driven by the worm thereby forming a helical gear, press fitted to the centre shaft and capable of making rotational movement with the centre shaft;
(h) a ROCKER ARM fitted to the centre shaft driven by the helical gear is capable of oscillating with respect to the centre shaft;
(i) a lock push rod disposed adjacent to the centre shaft and between the top plate and the bottom plate and driven by the ROCKER ARM, further capable of making axial movement;
(j) a leveller shaft driven by the lock push rod with thread mechanism, said shaft secured to the internal threads in the push rod, whereby the lock push rod and the leveller shaft move combinedly and correspondingly;
(k) a washer mounted below the top plate for arresting the axial play of central shaft;
(I) a pair of radial play control pin to arrest radial movement of the lock push rod,
such that the motor drives the ROCKER ARM to oscillate with respect to the helical gear which ROCKER ARM moves the lock push rod forward and backward axially.
12. The power supply means claimed in claims 1 to 6, is operable by leveller switch comprising of
(a) negative power supply connected to motor negative terminal end
(b) positive power supply connected to a first terminal T1 and second terminal T2;
(c) positive motor terminal connected to a third terminal T3;
(d) terminal T1 and T3 disposed 90° mutually apart with terminal T2 placed there in between and at the helical gear;
(e) a movable slider operable by the leveller switch adapted to contact along the said 3 terminals T1, T2 and T3 and contacting with terminal T3 continuously.
(f) said slider characterized to be movable between atleast zero, first, second and third position; and
(g) said terminals characterized in comprising of partial conductive portion and partial non-conductive portion such that the motor rotates for the duration when the slider is in the conductive portion of the terminal connected to the power supply, thereby enabling corresponding axial movement of the push rod for the purpose of leveling the head lamp.
13. The terminals claimed in Claim 12 comprising of
(a) terminal T3 comprising of only conductive material;
(b) terminal T1 and T2 comprising of both conductive and non-conductive material, with atleast two conductive portions and atleast two non- conductive portions in each terminal, said conductive and non-conductive portions alternating each other, further the said portions of the terminal T1 is different from the said portions of terminal T2.
14. The terminals claimed in Claim 13 wherein the said portions are variable corresponding to the desired axial movement of the push rod, thereby allowing variable axial movement distance by varying the conductive and non-conductive portions of a terminal.
15. An electromechanical Head Lamp leveller assembly having a leveller switch for guiding a head lamp mounted in head lamp housing in a vehicle with a leveller shaft operable by a lock-push rod mechanism comprising of
(a) a mechanical portion having a CAM mechanism driven by a DC motor operable by the a leveller switch to drive a push rod correspondingly in an axial direction;
(b) an electrical portion having a power supply means with atleast 3 terminals connected to the motor with a slider contacting the said terminals and operable by the leveller switch to supply power to the DC motor,
such that the lock push rod is continuously axiaily mechanically movable by CAM means corresponding to the rotary motion of the DC motor operated by the leveller switch to connect or interrupt the power supply to the DC motor from the supply means by positioning the slider selectively amongst the terminals.
5. An electromechanical Head Lamp leveller assembly having a leveller switch r guiding a head lamp mounted in head lamp housing in a vehicle with a leveller laft operable by a lock-push rod mechanism comprising of
a mechanical portion having a ROCKER ARM mechanism driven by a DC motor operable by the a leveller switch to drive a push rod correspondingly in an axial direction;
an electrical portion having a power supply means with atleast 3 terminals connected to the motor with a slider contacting the said terminals and operable by the leveller switch to supply power to the DC motor,
such that the lock push rod is continuously axially mechanically movable by ROCKER ARM means corresponding to the rotary motion of the DC motor operated by the leveller switch to connect or interrupt the power supply to the DC motor from the supply means by positioning the slider selectively amongst the terminals.