DEPARTMENT OF MECHANICAL ENGINEERING

DIFFERENTIAL BASED HEADLIGHT SYSTEM

SUBMITTED BY

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ABSTRACT

Our project is to make new and modern Directional Headlights in efficient manner by increasing the light angle.
that its lights will follow the mo ement of the front wheels. Directional headlights are those headlights that pro ide impro ed

lighting especially for cornering. !here are automobiles that ha e their headlights directly connected to the steering mechanism so

Our project comprises "am and #ollower mechanism$ %ear mechanism and spring mechanism. "am and #ollower mechanism is used to turn the head lights to right or left direction$ %ear mechanism is used to transmit motion and to reduce the no of rotations
from steering rod to cam shaft. Spring mechanism is used to bring back the

follower and head light bracket to its initial position.

&ccording to our project$ when the steering steers to the right$ the light bracket at right alone steers to right using cam ' follower mechanism and reduction gears ' ice ersa. &t the same time the left bracket remains stand still due to the dwell period of the cam. During the return stroke of cam$ the spring mechanism is used to bring the bracket and follower to its initial position. !he reduction gears are used to turn the brackets to the re(uired angle respecti e to the steering rotation. Our project will be useful for ehicles$ which are been used in hill areas
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1. INTRODUCTION

!he present in ention relates to headlights of an automobile$ more particularly to a direction turning de ice for headlights of an automobile which enables to turn direction

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synchronously with the rotation of the steering and hence increasing the safety for dri ing at night or in the darkness. ,n the known technology of the prior art$ a headlight of an automobile has a fi-ed line of emission which is aligned with the front direction of the automobile. &lthough the effects of .high beam. or .low beam. can be achie ed by adjusting the angle of ele ation of the headlight$ the direction of emission is not adjustable as to the left or right. /hen the road cur es or turns$ the corner on time when the car turns$ thereby creating a dead angle of illumination and such lack of isibility poses danger in dri ing at night or in darkness. !herefore$ it is highly desirable to in ent a de ice to sol e this problem and such de ice is of high utility. &n object of the present in ention is to pro ide a direction turning de ice for a headlight of an automobile which renders to emission direction of a headlight of an automobile in synchroni0ation with steering and thus increases the illuminated area upon changes of direction of the automobile when the automobile makes turns. ,n ancient Directional headlights$ /hen the steering steers to right or left direction$ then both the right and left headlights will steer to the perspecti e directions. ,t results in altering the optical a-is of the head light to the ehicle speed and the front road1 shape.

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3ut according to our project$ when the steering steers to right then the right side of the headlight bracket steers to right side and the left side headlight bracket remains stationery by cam mechanism and it is similar for the other side also. 3ecause of this$ the optical a-is of the headlight is widened and it is useful for the dri ers for safety ride.

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2. LITERATURE REVIEW

Our mechanism is not used elsewhere in any of the

ehicles. /e

performed a sur ey on this project with the lorry dri ers$ who tra el to hill stations often. 3ased on their (ueries$ we had indulged in this project.
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!he present in ention relates to a ehicle front lamp light distribution control system and more particularly to a distribution control system capable of raising ehicle front lamp light isibility at the time of

cornering by controlling light distribution means of the front lamp.

&ccording to 6apanese Patent Publication 7o. H21)*)14$ 6apanese Patent &pplication 8aid1Open 7o. H9119**92$ 6apanese Patent &pplication 8aid1 Open 7o. H11159452 and 6apanese Patent &pplication 8aid1Open 7o. H91 1:)45+ a ehicle head lamp including a fog lamp is pro ided with a mo able reflector and by turning the mo able reflector in the steering direction by an amount corresponding to a steering angle of the steering wheel$ the light distribution pattern of the front lamp is changed in the direction of ehicle;s turn so as to raise isibility at the time of cornering.

Howe er$ according to the aforementioned earlier art$ the light distribution pattern of the front lamp is changed in the steering direction of the steering wheel by an amount corresponding to the steering angle when the ehicle turns on an intersection or the like$ cornering destination cannot be beamed
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brightly enough before operating the steering wheel. !herefore$ an art capable of beaming the cornering destination prior to operation of the steering wheel has been demanded.

"0ech !atra and 1:)<s "adillacs were early implementer of such a techni(ue$ producing in the 1:*<s a ehicle with a central directional headlamp. !he &merican 1:+9 !ucker =edan was likewise e(uipped with a third central headlamp connected mechanically to the steering system. !he 1:45 #rench "itro>n D= and 1:5< "itro>n =? were e(uipped with an elaborate dynamic headlamp positioning system that adjusted the headlamps; hori0ontal and ertical positioning in response to inputs from the ehicle;s steering and suspension systems$ though @= regulations

re(uired this system to be deleted from those models when sold in the @=&.

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3. CONSTRUCTION

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!he main components used in this project areA

3.1 Spur Ge r!"

=pur gears are the simplest$ and probably most common$ type of gear. !heir general form is a cylinder or disk. !he teeth project radially$ and with these . straight-cut gears.$ the leading edges of the teeth are aligned parallel to the a-is of rotation. !hese gears can only mesh correctly if they are fitted to parallel a-is.

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3.2 Spr#$%e&!" & !pr#$%e& is a profiled wheel with metal teeth that meshes with a chain$ track or other perforated or indented material. =prockets are used to transmit rotary motion between two shafts where gears are unsuitable or to impart linear motion to a track$ tape etc.

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3.3 C ' ( )#**#+er"

"ams are basically shaped surfaces that are typically not round followerBpossibly a small wheelC is displaced as it mo es o er the surface.

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3., S&eer-./ !0!&e'"

!he most con entional steering arrangement is to turn the front wheels using a handle operated steering wheel which is positioned in front of the dri er$ ia the steering column$ which may contain uni ersal joints to allow it to de iate somewhat from a straight line. Other arrangements are sometimes found on different types of ehicles$ for e-ample$ a tiller or rear wheel steering. !racked ehicles such as tanks usually employ differential steering that is$ the tracks are made to mo e at different speeds or e en in opposite directions to bring about a change of course.

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3.1 L-/2& 3r $%e&" Headlamps must be kept in proper alignment Bor .aim.C. Degulations for aim ary from country to country and #rom beam specification to beam specification. !his gi es all roughly e(ual seeing distance and all dri ers roughly e(ual glare. ehicles

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3.4 Fr 'e! Fr '-./$ in construction known as *-/2& )r 'e $#.!&ru$&-#.$ is a building techni(ue based around structural members$ usually called studs$ which pro ide a stable frame to which interior and e-terior wall co erings are attached$ and co ered by a roof comprising hori0ontal joists and sloping rafters or manufactured roof trusses co ered by arious sheathing materials. 8ight frame material dimensions range from *9 mm by 9: mm B1.2 by *.2 inches E i.e. a two1by1fourC to 2 cm by *< cm Btwo1by1twel e inchesC at the cross1section$ and lengths ranging from ).2 m B9 feetC for walls to 5 m B)< feetC or more for joists and rafters.

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3.5 C2 -. 6r-7e"

"ommonly$ mechanical energy from a motor or other source applied to a sprocket wheel is con eyed by means of an endless chain to another sprocket wheel for dri ing a mechanism. F-amples of such an arrangement are found in bicycles$ motorcycles$ and con eyor belts.

!he chain in this application is so designed that each consecuti e link fits o er a sprocket$ the distance between links being called the pitch. !he relati e speed of the wheels aries according to their relati e circumferences and$ thus$ the number of sprockets on each.

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,. WOR8ING METHODOLOGY

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Our project is to the turn the right light bracket to the right$ when the ehicle turns to right lea ing the left bracket to remain in standstill position$ and ice ersa.

/hen the steering steers to the right$ a sprocket attached to the steering rod rotates which in turn connected to the other sprocket through a chain. !he si0es of the sprockets were designed in such a way that$ if the smaller sprocket rotates four full complete rotations the larger sprocket will rotate once. &lso the small gear$ which is attached to the same shaft as of the

larger sprocket$ also rotates along with the sprocket.

& larger gear of the former is chosen$ which is twice its diameter$ is meshed to transmit the motion. &fter this$ the rotation of cam is achie ed by fi-ing the cam in the same shaft of the larger gear. !he spherical edged follower is attached to the cam is used to con ert the rotary motion of cam into reciprocating motion. =o the right light bracket mo es according to the mo ement of the follower. &t the same time$ the cam at the other end remains in the dwell period$ which results in the stand still position of the light bracket.
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!he light bracket will returns back to its original position$ using the spring mechanism attached to it.

/hen the ehicle turns to left$ the left bracket alone turns to the left lea ing the right light bracket in standstill position.

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INITIAL HEADLIGHT POSITION

FINAL HEADLIGHT POSITION

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1. DESIGN CALCULATIONS

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1.1. De!-/. $ *$u* &-#. )#r $2 -. 6r-7e

=peed of rotation$ 71 G 1<<< rpm =peed of rotation$ 7) G )2< rpm "entre distance$ a G 9<< mm

%ear ratio$ i G 71H7) G + istd G + !eethes$ 01 G )< !eethes$ 0) G i I 01 G 9< teeth

"hain pitch$ a G B*< J 2<C p a G *<p GK pG )4.45 mm Gpmaa G 2<p GK pG 14 mm Gpmin =tandard pitch$ p std G)2.+ mm

=o the chain selected is 14&11D9<1K simple8ength of chain$ lp G )ap L B01L0)CH)LBB0)101CH)C)Hap

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ap G aoHp G 9<<H)2.+ G *1.+: lp G B)I*1.+:CL2<LB4<H)I*.1+C)H*1.+: G 112.95 G 114 links &ctual length G no. of links I pitch G ):+4.4 mm 3earing area G 1.5: mm) "entre distance$ a G BBeLMBe) 19mCCH+Cp e G lp J B01L0)CH) G 44 m G BB0)101CHB)I*.1+CC) G :1.19 a G 44LMBBB44) J B9I:1.19CCH+Cp G 9<1.2 mm 1.2. De!-/. $ *$u* &-#. )#r $2 -. 6r-7e =peed of rotation$ 71 G 1<<< rpm =peed of rotation$ 7) G )2< rpm "entre distance$ a G 1)<< mm

%ear ratio$ i G 71H7) G + istd G + !eethes$ 01 G )< !eethes$ 0) G i I 01 G 9< teethes

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"hain pitch$ a G B*< J 2<Cp a G *<p GK pG +< mm Gpmaa G 2<p GK pG )+ mm Gpmin =tandard pitch$ p std G)2.+ mm =o the chain selected is 14&11D9<1K simple8ength of chain$ lp G )ap L B01L0)CH)LBB0)101CH)C)Hap ap G aoHp G 1)<<H)2.+ G +5.)+ lp G B)I+5.)+CL2<LB4<H)I*.1+C)H+5.)+ G 1++.+: G 1+4 links &ctual length G no. of links I pitch G *5<9.+ mm 3earing area G 1.5: mm) "entre distance$ a G BBeLMBe) 19mCCH+Cp e G lp J B01L0)CH) G :4 m G BB0)101CHB)I*.1+CC) G :1.19 a G :4LMBBB:4) J B9I:1.19CCH+Cp G 11:+.2 mm

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1.3. R#& &-#. re6u$&-#. r &-#! =teering rotation G 5)<< &ngle of cam to be tilted G :<< =o alue of angle to be reduced is in ratio 9A1 !he reduction between the sprockets is made as +A1 =o the diameter ' teeth of the larger sprocket should be four times that of the smaller Diameter$ d1 G +< mm !eethes$ 01 G )< Diameter$ d) G 14< mm !eethes$ 01 G 9<

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1.,. De!-/. $ *$u* &-#. )#r !pur /e r!

=peed of rotation$ 71 G 1<<< rpm =peed of rotation$ 7) G 2<< rpm %ear ratio$ i G 71H7) G )

&ssuming the same material for pinion and gear 147i 1 "r9< 8ife of gear G )<$<<< hours 7umber of cycles G )<$<<<I4<I71 G )<$<<<I4<I1<<< G 1.)I1<: cycles NoungOs modulus$ F G ).12I1<4 kgfHcm) G ).12I1<2 7Hmm) Design contact stress$ PQcR G "D I HD"IScl "D G *1<$ HD" G 4<$ SclG 1 Tfrom psg tech data book pg.7o.9.15U PQcR G 19.4 I 1<) 7Hmm)

Design bending stress$ PQbR G BB1.+ISblIQ11CHBnISQCC

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7 G )$ SQ G 1.)$ Sbl G 1 Q11 G <.)2Qu L 1)<< Qu G 1<<< 7Hmm) Q11 G +5<<< 7Hcm) PQbR G )5+.14 7Hmm) k.kd G 1.* ko G 1.2Bmedium shockC !eethes$ 01 G )< !eethes$ 0)G iI01 G +<

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1.1. De!-/. $ *$u* &-#. )#r !pr#$%e&!

Here the rotation reduction ratio is +A1 =o the diameter ' teeth of larger sprocket should be four times that of the smaller. Diameter$ d1 G +< mm Preadily a ailable in marketR !eethes$ 01 G )< Diameter$ d) G 14< mm !eethes$ 0) G 9<

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1.4. De!-/. $ *$u* &-#. )#r $ ' ( )#**#+er

O& G initial position of light bracket B5inchesC &3 G final position of light bracket O3 G distance mo ed by the bracket

=troke length G 1<).4 mm "am diameter G 12< mm #ollower length G 1<).4 mm

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1.5. Spr#$%e& ( Ge r 6e& -*!9 +e !e*e$&e6 6ue &# 7 -* 3-*-&0 -. ' r%e&"

S.N#. 1. ). *. +.

C#'p#.e.& =mall =procket 8arge =procket =mall %ear 8arge %ear

M &er- * ?ild steel ?ild steel ?ild steel ?ild steel

N#. #) &ee&2e! )< 9< )< +<

D- 'e&er +< 14< +< 9<

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4. RESULT ( FUTURE APPLICATIONS

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4.1 ADVANTAGES @seful for hea y ehicles in hill areas$ where hair1pin bends are more. =afe riding &ccident free roads =imple in structure ?ind free dri ing

4.2 LIMITATIONS 7ot mandatory for straight roads.

4.3 APPLICATIONS "an be used in all hea y ehicles. "an be used in tempo and ans.

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5. BIBLIOGRAPHY

1. 3ook on Design of ?achine Flements by S.V.7&!&D&6&7 ). 3ook on Design of !ransmission =ystems by V.3&7D&D, *. P=% Design Data 3ook. +. www.wikipedia.com

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