AUTOMATIC HEAD LAMP ALIGNMENT SYSTEM

PROJECT REPORT

2018 -2019

Submitted by
RUBANKUMAR.M 17241937
VIGNESH.V 17241944
VIJAYAKUMAR.R 17241945
VIJAYAMOORTHY.A 17241946
VISHNUVARDHAN.A 17241947
HARISH DARWIN.V 17266570

Guided by
Mr. V.KAVINKUMAR M.E.,

` As Partial fulfilment of the requirements for the award of

Diploma in Automobile Engineering of DOTE, Chennai, Tamilnadu

During the year of 2018-2019.

DEPARTMENT OF AUTOMOBILE ENGINEERING

THE CHRISTIAN INSTIUTE FOR TECHNICAL EDUCATION

(CHRISTIAN POLYTECHNIC COLLEGE), ODDANCHATRAM – 624619.
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THE CHRISTIAN INSTIUTE FOR TECHNICAL EDUCATION
(CHRISTIAN POLYTECHNIC COLLEGE)

ODDANCHATRAM - 624619

BONAFIDE CERTIFICATE

This is to certify that this is the Bonafide record of the project work titled

“AUTOMATIC HEAD LAMP ALIGNMENT SYSTEM” Carried out

by the ………………………………………………….. As partial
fulfillment of the requirements for an award of Diploma in Automobile
Engineering of the state board of Technical Education, Chennai – 25,
Tamilnadu during the year of 2018 - 2019.

Project Guide Head of the Department

V.KAVINKUMAR M.E., C.S.SAKTHIVEL M.TECH.,

Submitted for the Board of Examination held on…………...

Internal Examiner External Examiner

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 ACKNOWLEDGEMENT

We thank the Lord Almighty for the blessings and make us to carry out this project
successfully.

We would like to express our gratitude to our Founder “Padma Bhushan” (Late)
Dr. Jacob Cherian B.Sc., MBBS., FRCS(Ed)., FRCS (GI)., FICA., FICA, FAIS., and
our Co-Founder (Late) Mrs. Dr. Mary Cherian, MBBS.,DMCW., DCH(Lon).,
FRCP(Ed)., FRCP(GI)., for their Blessings.

Also We heartily thank our Director Mrs. Dr. Shila Thomas, M.B.B.S., D.O.,
FSVH., (Germany) and our beloved President Dr. P. Thomas Cherian MBBS, FRCS
GLASG(G.Surg), FRCS (Intercollegiate), CCST (UK)., for providing us all the
facilities in our Institution.

Our sincere thanks to our Correspondent Rev. Dr. E. Richard, M.A., M.Ed., B.D.,
for granting approval to utilize all the facilities of the institute to complete the project work
in an efficient manner.

We express our deepest sense of gratitude to our respected Principal Prof. P.X.
Britto B.E., M.E., PhD*, MISTE. for his kind guidance, support and valuable suggestions
during the course of our project work.

We extend our heartfelt thanks to our beloved Head of the Department

Mr.C.S.SAKTHIVEL M.TECH., for his valuable suggestions, perennial patronage and
encouragement during this project work.

We would like to extend sincere thanks to Our Guide Mr.V.KAVINKUMAR M.E.,

who gave us advice, guidance, encouragement and valuable suggestions all through our
project work.

Finally our heartiest and grateful thanks to our Teaching and Non-teaching Staff
Members of our Department and our loved parents for their encouragement which has been
a regular source of inspiration with great interest during our project work.

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AUTOMATIC HEAD LAMP
ALIGNMENT SYSTEM

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CONTENT’S

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 TABLE OF CONTENTS

S.NO PARTICULARS PAGE NO

1 SYNOPSIS 7

2 PROJECT PLANING 10

3 INTRODUCTION 14

4 LITERATURE REVIEW 16

5 HISTORY OF 18
DEVELOPMENT
6 CONSTRUCTION 20

7 WORKING PRINCIPLE 25

8 DESIGN CALCULATIONS 28

9 DIAGRAM 32

10 ADVANTAGES 39

11 APPLICATIONS 41

12 COST OF ESTIMATION 43

13 CONCLUSION 45

14 BIBLOGRAPHY 47

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1. SYNOPSIS

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 SYNOPSIS

As for Indian road transport scenario is concerned, accidents are becoming

a day to day cause an attempt has been made in this project to reduce such
mishaps. In our project of “AUTOMATIC HEAD LAMP ALIGNMENT
SYSTEM” having the following operation occurs automatically in the vehicle.

These type of headlights appeared on production cars in the 1920’s and are
stillaround nowadays, but not very popular, although they make night time
driving safer. The most famous car which featured these lights was the Citroen
DS (1955-1975), introduced on the 1968 Paris Motor Show. The headlights can
be connected to the steering linkage by means of rods or cables, operated
hydraulically by the power steering or nowadays electronically adjusted, even
controlled by satellite navigation system.

Our project is to make new and modern “Directional Headlights” in efficient

manner by increasing the light angle. Directional headlights are those headlights
that provide improved lighting especially for cornering. There are automobiles
that have their headlights directly connected to the steering mechanism so that its
lights will follow the movement of the front wheels.

Our project comprises Cam and Follower mechanism, Gear mechanism and
spring mechanism. Cam and Follower mechanism is used to turn the head lights
to right or left direction, Gear 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.

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According 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
& vice versa. At 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. The reduction gears are
used to turn the brackets to the required angle respective to the steering rotation.

Our project will be useful for vehicles, which are been used in hill areas

The 1968 Citroen DS featuring directional- headlights

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2. PROJECT PLANING

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 PROJECT PLANING

Before staring every project its planning is to be done. Planning is very important
task and should be taken with great care, as the efficiency of the whole project
largely depends upon its planning while planning a project each and every details
should be worked out in anticipation and should carefully is considered with all
the relating provisions in advance. Project planning consists of the following
steps.

PROJECT CAPACITY:

The capacity of the project must be decided considering the amount of money
which can be invested and availability of material and machines.

DRAWINGS

Drawing been decided for the project to be manufacture. Its detailed drawing
specification for raw material and finished products should be decided carefully
along with the specification of the machines required for their manufacture.

MATERIAL EQUIPMANT:

The list of materials required for manufacture is prepared from the

drawings. The list of is known as “BILL OF MATERIALS”. This passes to the
store keeper and the required materials taken from the store under permission of
store keeper operation, the necessity of operation, the person to do the job,
machine to be used to do the job are considered while planning the operation.
After considering tea above questions a best method is developed and the best
method is applied to the operation.

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MACHINE LOADING:

While planning proper care should be taken to fine the machining time for each
operation as correct as possible. So that the arrangement for full utilization of
machine can be made machine loading programmed is also known.

PURCHASE CONSIDERATION:

It is different to manufacture all the component needed for the equipment in the
workshop it self. The decision about a particular item whether to purchase or to
manufacture is taken by planning after making through study of relative merits
demerits.

EQUIPMENT CONSIDERATION:

Result obtained from “PROCESS PLANNING” and “MACHINE LODING”

helps in calculation the equipment requirement specification of the equipment
should be laid down by considering the drawing. Drawing will also help in

deciding and necessary requirement of tools, accessories.

COST CALCULATION:

The cost of the project can be calculated by adding following.

1.Material Cost

2.Machining Cost

3.Overhead Expenses.

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COMPARISION:

The various items in the finished project are compared to the standards for the
further correction.

REPORT:
At the end of the project work report is prepared for future references. The
report consists of all the items done the project work.

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3. INTRODUCTION

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 INTRODUCTION

The present invention relates to headlights of an automobile, more particularly to

a direction turning device for headlights of an automobile which enables to turn
direction synchronously with the rotation of the steering and hence increasing the
safety for driving at night or in the darkness.

In the known technology of the prior art, a headlight of an automobile has a fixed
line of emission which is aligned with the front direction of the automobile.
Although the effects of "high beam" or "low beam" can be achieved by adjusting
the angle of elevation of the headlight, the direction of emission is not adjustable
as to the left or right. When the road curves or turns, the corner on time when the
car turns, thereby creating a dead angle of illumination and such lack of visibility
poses danger in driving at night or in darkness.

Therefore, it is highly desirable to invent a device to solve this problem and such
device is of high utility.

An object of the present invention is to provide a direction turning device for a

headlight of an automobile which renders to emission direction of a headlight of
an automobile in synchronization with steering and thus increases the illuminated
area upon changes of direction of the automobile when the automobile makes
turns.

In ancient Directional headlights, when the steering steers to right or left direction,
then both the right and left headlights will steer to the perspective directions. It
results in altering the optical axis of the head light to the vehicle speed and the
front road-shape.

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But 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.

4. LITERATURE REVIEW

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 LITERATURE REVIEW

The present invention relates to a vehicle front lamp light distribution control
system and more particularly to a vehicle front lamp light distribution control
system capable of raising visibility at the time of cornering by controlling light
distribution means of the front lamp.

According to-

 Japanese Patent Publication No. H5-23216,

 Japanese Patent Application Laid-Open No. H8-183385,
 Japanese Patent Application Laid-Open No. H11-78675, and
 Japanese Patent Application Laid-Open No. H8-192674

A vehicle head lamp including a fog lamp is provided with a movable reflector
and by turning the movable 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 vehicle's turn so as to raise
visibility at the time of cornering.

However, 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 vehicle turns on an
intersection or the like, cornering destination cannot be beamed brightly enough
before operating the steering wheel. Therefore, an art capable of beaming the
cornering destination prior to operation of the steering wheel has been demanded.

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5. HISTORY OFDEVELOPMET

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 HISTORY OF DEVELOPMET

Although the concept of headlights that follow the movements of the steering is
still considered nowadays as being innovative, it is not new. The first vehicles
fitted with such systems appeared in the 1920s. Pioneers and milestones in the
automotive history featuring directional headlights were the 1928 Willis - Knight
70A Touring, the 1930s Czech Tetra and the American 1948 Trucker Sedan.
These cars were equipped with a third central headlight mechanically connected
to the steering system. The most famous car featuring directional headlights, was
the Citroen DS (1955-1975), introduced on the 1968 Paris Motor Show. This car
had both headlights not only swiveling with the steering, but they were self
leveling as well, responding to inputs from the suspension. While it was a purely
mechanical system operated by cables, the 1970Citroen SM used a sealed
hydraulic system with a glycerin based fluid. On present day motorcars two types
of directional headlight system are in use:

1. A fixed light that only turns on and off based on steering and vehicle speed.
2. The light is motorized by the use of small electric motors and physically
swivels according to the movement of the steering wheel and vehicle speed.

This modern technology first appeared in 2003 on the Porsche Cayenne (fixed)
and the Mercedes E-class (motorized). Soon other manufacturers followed them
such as the BMW with the adaptive headlights and cornering lights and nowadays
most of the main brands use such systems on their vehicles like Acura, Audi,
BMW, Cadillac, Ford, Infiniti, Jaguar ,Land Rover,Lexus,Mercedes-
Benz,Opel,Porsche,Saab,Volkswagen,VolvoandMazda.Audi is experimenting with
a system which uses satellite navigation adjust the headlights according to the
road layout ahead the vehicle

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6. CONSTRUCTION

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 CONSTRUCTION

The main components used in this project are:

1.Rack and pinion Gears:

These gears are the simplest, and probably most common, type of gear. Their
general form is a cylinder or disk. The teeth project radically outward, and with
these "straight-cut gears", the leading edges of the teeth are aligned parallel to the
axis of rotation. These gears can only mesh correctly if they are fitted to parallel
axis.

2.Sprockets:

A sprocket is a profiled wheel with metal teeth that meshes with a chain, track or
other perforated or indented material. Sprockets 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.Cam & follower:

Cams are basically shaped surfaces that are typically not round follower(possibly
small wheel) is displaced as it moves over the surface.

4. Steering system:

The most conventional steering arrangement is to turn the front wheels using a
handle operated steering wheel which is positioned in front of the driver, via the
steering column, which may contain universal joints to allow it to deviate
somewhat from a straight line. Other arrangements are sometimes found on
different types of vehicles.

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For example, a tiller or rear wheel steering.

Tracked vehicles such as tanks usually employ differential steering that is, the
tracks are made to move at different speeds or even in opposite directions to bring
about a change of course.

5.Light brackets:

Headlamps must be kept in proper alignment (or "aim"). Regulations for aim vary
from country to country and from beam specification to beam specification. This
gives all vehicles roughly equal seeing distance and all drivers roughly equal
glare.

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6.Frames:

Framing, in construction known as light frame construction, is a building

technique based around structural members, usually called studs, which provide
a stable frame to which interior and exterior wall coverings are attached, and
covered by a roof comprising horizontal joists and sloping rafters or manufactured
roof trusses covered by various sheathing materials. Light frame material
dimensions range from 38 mm by 89 mm (1.5 by 3.5 inches — i.e. a two-by-four)
to 5 cm by 30 cm (two-by-twelve inches) at the cross-section, and lengths ranging
from 2.5 m (8 feet) for walls to 7 m (20 feet) or more for joists and rafters.

7.Chain drive:

Commonly, mechanical energy from a motor or other source applied to a sprocket

wheel is conveyed by means of an endless chain to another sprocket wheel for
driving a mechanism. Examples of such an arrangement are found in bicycles,
motorcycles, and conveyor belts.

The chain in this application is so designed that each consecutive link fits over a
sprocket, the distance between links being called the pitch. The relative speed of
the wheels varies according to their relative circumferences and, thus, the number
of sprockets on each.

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7. WORKING PRINCIPLE

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 WORKING PRINCIPLE

Our project is to the turn the right light bracket to the right, when the vehicle turns
to right leaving the left bracket to remain in standstill position, and vice versa.

When 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. The sizes 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. Also the small gear,
which is attached to the same shaft as of the larger sprocket, also rotates along
with the sprocket.

A larger gear of the former is chosen, which is twice its diameter, is meshed to
transmit the motion. After this, the rotation of cam is achieved by fixing the cam
in the same shaft of the larger gear. The spherical edged follower is attached to
the cam is used to convert the rotary motion of cam into reciprocating motion. So
the right light bracket moves according to the movement of the follower. At the
same time, the cam at the other end remains in the dwell period, which results in
the stand still position of the light brackets.

The light bracket will returns back to its original position, using the spring
mechanism attached to it.

When the vehicle turns to left, the left bracket alone turns to the left leaving the
right light bracket in standstill position.

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INITIAL HEADLIGHT POSITIONFINAL HEADLIGHT
POSITION

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8. DESIGN CALCULATIONS

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 DESIGN CALCULATIONS

1. Design calculation for chain drive

Speed of rotation, N1 = 1000 rpm

Speed of rotation, N2 = 250 rpm

Centre distance, a = 800 mm

Gear ratio, i = N1/N2 = 4

istd = 4

Teethes, z1 = 20

Teethes, z2 = i * z1 = 80 teeth

Chain pitch, a = (30 – 50) p

a = 30p => p= 26.67 mm =pmax

a = 50p => p= 16 mm =pmin

Standard pitch, pstd =25.4 mm

So the chain selected is 16A1-R80-> simplex

Length of chain,lp = 2ap + (z1+z2)/2+((z2-z1)/2)2/ap

ap = ao/p = 800/25.4 = 31.49

lp = (2*31.49)+50+(60/2*3.14)2/31.49

= 115.87

= 116 links

Actual length = no. of links * pitch

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 = 2946.6 mm

Bearing area = 1.79 mm2

Centre distance, a = ((e+√(e2-8m))/4)p

e = lp – (z1+z2)/2 = 66

m = ((z2-z1)/(2*3.14))2

= 91.18

a = 66+√(((662– (8*91.18))/4)p = 801.5 mm

2. Design calculation for chain drive

Speed of rotation, N1 = 1000 rpm

Speed of rotation, N2 = 250 rpm

Centre distance, a = 1200 mm

Gear ratio, i = N1/N2 = 4

istd = 4

Teethes, z1 = 20

Teethes, z2 =i * z1 = 80 teethes

Chain pitch, a = (30 – 50)p

a = 30p => p= 40 mm =pmax

a = 50p => p= 24 mm =pmin

Standard pitch, pstd =25.4 mm

So the chain selected is 16A1-R80-> simplex

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Length of chain,

lp = 2ap + (z1+z2)/2+((z2-z1)/2)2/ap

ap = ao/p = 1200/25.4 = 47.24

lp = (2*47.24)+50+(60/2*3.14)2/47.24

= 144.49

= 146 links

Actual length = no. of links * pitch

= 3708.4 mm

Bearing area = 1.79 mm2

Centre distance, a = ((e+√(e2-8m))/4)p

e = lp – (z1+z2)/2 = 96

m = ((z2-z1)/(2*3.14))2

= 91.18

a = 96+√(((962– (8*91.18))/4)p= 1194.5 mm

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3. Rotation reduction ratios

Steering rotation = 7200

Angle of cam to be tilted = 900

So value of angle to be reduced is in ratio 8:1

The reduction between the sprockets is made as 4:1

So the diameter & teeth of the larger sprocket should be four times that of the
smaller

Diameter, d1 = 40 mm

Teethes, z1 = 20

Diameter, d2 = 160 mm

Teethes, z1 = 80

4. Design calculation for spur gears

Speed of rotation, N1 = 1000 rpm

Speed of rotation, N2 = 500 rpm

Gear ratio, i = N1/N2 = 2

Assuming the same material for pinion and gear16Ni 1 Cr80

Life of gear = 20,000 hours

Number of cycles = 20,000*60*N1

= 20,000*60*1000

= 1.2*109

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Cycles Young’s modulus, E = 2.15*106kgf/cm2

= 2.15*105N/mm2

Design contact stress, [σc] = CR * HRC*Kcl

CR = 310, HRC = 60, Kcl= 1 {from psg tech data book pg.No.8.17}

[σc] = 18.6 * 102N/mm2

Design bending stress, [σb] = ((1.4*Kbl*σ-1)/(n*Kσ))

N = 2, Kσ = 1.2, Kbl = 1

σ-1 = 0.25σu + 1200

σu = 1000 N/mm2

σ-1 = 47000 N/cm2

[σb] = 274.16 N/mm2

k.kd = 1.3

ko = 1.5(medium shock)

Teethes, z1 = 20

Teethes, z2= i*z1 = 40

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5. Design calculation for sprockets

Here the rotation reduction ratio is 4:1

So the diameter & teeth of larger sprocket should be four times that of the smaller.

Diameter, d1 = 40 mm [readily available in market]

Teethes, z1 = 20

Diameter, d2 = 160 mm

Teethes, z2 = 80

6. Design calculation for cam & follower

OA = initial position of light bracket (7inches)

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AB = final position of light bracket

OB = distance moved by the bracket

Stroke length = 102.6 mm

Cam diameter = 150 mm

Follower length = 102.6 mm

7. Sprocket & Gear details, we selected due to availability

in market:

S. No. Component Material No. of teeth Diameter

1 Small Sprocket Mild steel 20 40
2 Large Sprocket Mild steel 80 160
3 Small Gear Mild steel 20 40
4 Large Gear Mild steel 40 80

Real life road traffic situations

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Negotiating a bend

With directional headlight without directional headlight

Arriving at a junction

With directional headlight Without directional headlight

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9. DIAGRAM

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 DIAGRAM

FIG: AUTOMATIC HEAD LAMP ALIGNMENT SYSTEM

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10. ADVANTAGES

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 ADVANTAGES

• Useful for heavy vehicles in hill areas, where hair-pin bends are more.

• Safe riding

• Accident free roads

• Simple in structure

• Mind free driving

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11. APPLICATIONS

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 APPLICATIONS

• Can be used in all heavy vehicles.

• Can be used in tempo and vans.

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12. COST OF ESTIMATION

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 COST OF ESTIMATION

RATE AMOUNT
S.NO COMPONENTS NAME QTY
RS/= RS/=
1. Head light 2 500 1000
2. wheel 4 300 1200
3. Steering 1 1000 1000
4. Rack and pinion gear with 1 1300 1300
rods
5. Assembly charge _ 800 800
Total Rs.5300

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13. Conclusions

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 Conclusions

Before we undertook this project our knowledge about directional headlights was
limited. After doing an extensive research for this project we have a wider
knowledge of this field in automotive technology, learnt useful information about
different types of directional headlights. We have searched the library of the
college for relevant books and the internet for additional information. During the
build of an experimental model of directional headlights on a vehicle we have
improved our DIY skills and technical problem solving ability .Carrying out test
with the project vehicle has proved that this concept works and although such
lights are not widely used even nowadays, it does support the driver’s vision
during night-time driving, helps to reduce black spots while cornering and
therefore reduces the risk of accidents, by helping to notice persons or objects
hidden in a bend earlier in advance. We are looking forward to see more road
vehicles equipped with directional headlights in serial production.

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14. BIBLIOGRAPHY

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 BIBLIOGRAPHY

Library:

Birch, Thomas W. (1993) Automotive suspension and steering systems. Fort

Worth: Saunders College Publishing

Denton, Tom. (2000) Automobile electrical and electronic systems. W.

International

Erlanger, Herbert E. and Hathaway, Richard B. (1989) Automotive suspension

and steering systems. Englewood Cliffs, N.J.: Prentice Hall Rundle, Steve (2005)

Ford Fiesta service and repair manual, Oct 1995-Mar 2002 (N to 02registration)
petrol and diesel. Spark ford, Somerset: Haynes Service Publications (1995)

Owner’s guide, Fiesta.5th edition. Brentwood, Essex: Ford Motor Company Ltd.

PSG Design Data Book

Internet:

BMW Group <URL: http://www.bmw.com>

Citroen ID/DS Club Nederland <URL: http://www.citroeniddsclub.nl>

Wiki cars<URL: http://wikicars.org/en>

Wikipedia <URL: http://en.wikipedia.org>

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