A

Project Report On

FABRICATION
OF
ADAPTIVE

HEADLIGHT

SYSTEM

Submitted to

CHHATTISGARH SWAMI VIVEKANAND TECHNICAL UNIVERSITY

BHILAI
In partial fulfillment of requirement for the award of degree
Of

Bachelor of Engineering
In

Mechanical Engineering
By

ANANT NADAMWAR
RAVI SHANKER NAG
SANDEEP SAHA

Department of Mechanical Engineering

Rungta College of Engineering & Technology
Kohka-Kurud Road, Kurud, Bhilai-490024
Phone no. : 0788-2286476,77, Fax-0788-2286480

Session : 2011-2012

DECLARATION
I the undersigned solemnly declare that the report of the project work entitled
FABRICATION OF ADAPTIVE HEADLIGHT SYSTEM , is based my own work
carried out during the course of my study under the supervision of Mr. Sanjay Kumar
Dewangan.
I assert that the statements made and conclusions drawn are an outcome of the project
work. I further declare that to the best of my knowledge and belief that the report does not
contain any part of any work which has been submitted for the award of any other
degree/diploma/certificate in this University or any other University.

(Signature of the student)

Name: Sandeep Saha

Roll No.: 3133707089
Enrollment No.: AB5728

CERTIFICATE
This is to certify that the report of the project submitted is an outcome of the project work
entitled FABRICATION OF ADAPTIVE HEADLIGHT SYSTEM carried out by
Sandeep Saha bearing Roll No.: 3133707089 & Enrollment No. : AB5728, Batch 2011-12
carried out under my guidance and supervision for the award of Degree in Bachelor of
Engineering in Mechanical Engineering of Chhattisgarh Swami Vivekananda Technical
University, Bhilai (C.G.), and India.

To the best of my knowledge the report

i)

Embodies the work of the candidate him/herself,

ii)

Has duly been completed,

iii)

Fulfils the requirement of the Ordinance relating to the BE degree of the

University and

iv)

Is up to the desired standard for the purpose of which is submitted.

(Signature of the Guide)

Mr. Sanjay Kumar Dewangan
Assistant Professor: Mechanical Department

Department of Mechanical Engineering

Rungta College of Engineering & Technology
Kurud Road, Kohka, Bhilai -490024
The project work as mentioned above is hereby being recommended and forwarded for
examination and evaluation.
(Signature of Head of Department with seal)
3

CERTIFICATE BY THE EXAMINERS

This is to certify that the project work entitled Fabrication of Adaptive Headlight
System.
Submitted by:-

Anant Nadamwar

Roll No. : 3133705006

Enrollment No. : AA2512

Ravi Shankar Nag

Roll No. : 3133707084

Enrollment No. : AD5722

Sandeep Saha

Roll No. : 3133707089

Enrollment No. : AB5728

Has been examined by the undersigned as a part of the examination for the award of
Bachelor of Engineering degree in Mechanical Engineering of Chhattisgarh Swami
Vivekananda Technical University, Bhilai.

Internal Examiner
Date:

External Examiner
Date:

ACKNOWLEDGEMENT

We would like to express our sincere thanks towards the Head of Department of Mechanical
Engineering of Rungta College of Engineering & Technology and acknowledge to Mr.
Sanjay Kumar Dewangan our project guide as our advisor for his continual patience,
encouragement and guidance. All we would like to extend our thanks to other respected
teachers of Mechanical department those who guide us & lifted knowledge in us.

(Signature of the student)

Name: Anant Nadamwar
Roll No.: 3133705006
Enrollment No.: AA2572

(Signature of the student)

Name: Ravi Shankar Nag
Roll No.: 3133707084
Enrollment No.: AB5722

(Signature of the student)

Name: Sandeep Saha
Roll No.: 313377089
Enrollment No.: AB5728

Department of Mechanical Engineering

Rungta College of Engineering & Technology
Kurud Road, Kohka, Bhilai-490024
5

ABSTRACT
According to traffic accident data, the majority of severe road accidents occur at
night. Therefore, it is of great importance to use available technology to contribute to
road safety by improving the visual conditions provided by vehicle headlights. This
project presents the hardware in the loop simulation of an Adaptive Headlight
System for motor vehicles.The Adaptive Headlight System is an active safety
system, where the head lamp orientation control system rotates the right and left low
beam headlights independently and keeps the beam as parallel to the curved road
as possible to provide better night time visibility.

TABLE OF CONTENTS

TITLE

PAGE

TITLE PAGE

DECLARATION

CERTIFICATE

CERTIFICATE BY ACKNOWLEDGEMENT

ACKNOWLEDGMENT

ABSTRACT

TABLE OF CONTENTS

LIST OF FIGURES

1.

INTRODUCTION

2.

LITERATURE REVIEW

10

3.

PROBLEM DEFINITION

13

4.

METHODOLOGY

15

5.

RESULT

23

6.

CONCLUSION

24

7.

BIBLIOGRAPHY

25

LIST OF FIGURES

TITLE

FIG 1.1
FIG 2.1
FIG 3.1
FIG 4.1
FIG 4.2

ILLUMINATION PATTERN
TRANSMISSION MECHANISM
PROJECTION OF LIGHT
STEERING SYSTEM
STEERING LINKAGE FOR VEHICLES

PAGE
09
10
14
16
17

WIYH RIGID AXLE FRONT SUSPENSION

FIG 4.3

STEERING LINKAGE FOR VEHICLES

18

WITH INDEPENDENT FRONT AXLE

SUSPENSION

FIG 4.4 WORM & WHEEL STEERING GEAR

FIG 4.5 RACK & PINION STEERING GEAR
FIG 4.6 CONVENTIONAL ARRANGEMENT
FIG 4.7 MOVEABLE HEADLIGHT ARRANGEMENT

19
20
21
22

CHAPTER 1

INTRODUCTION
A four wheeler usually find difficulty to drive especially at sharp turn .The model helps them
to change the focus of headlight as the steering move on either direction. Adaptive headlights
react to the steering system of the car and automatically adjust to illuminate the road wheel.
When the car turns right, the headlight angles to the right. Turn the car left ,the headlights
angles to the left.
Instead of moving the headlights, reflectors are fitted on the inside on either side of the
headlamp casing. These reflectors are moved to direct a beam in the same direction as the
movement of the vehicle .The power required to move the reflectors is transmitted using
hydraulic linkages.

Fig.1.1 Illumination Pattern During Turn Activation

CHAPTER 2

LITERATURE REVIEW
In past different researchers presented their work on Steering wheel controlled mechanism,
the important literature reviews are as follows

Kobayashi [1], discussed the new standard for cornering light system allows not only the
conventionally approved ONOFF control mode interlocked with the operation of the turn
signal switch but also an automatic ON-OFF control according to the steering wheel angle.
The active cornering light system (ACL system) on the new DELICA D: 5 have a dedicated
ECU to control the operation of the lamps. In addition, the light distribution of the ACL
system is coordinated with that of the high-intensity discharge headlights to offer higher
nighttime visibility of road shoulders at intersections. In recent years, global harmonization of
automotive regulations has led to changes in Japanese vehicle equipment and design. This
paper also introduced change in regulatory requirements regarding lighting equipment and
the accommodation of such changes by the vehicle design.
Chi on-dong lin [2], proposed by car light piloting system objective of the present
invention is to provide a steering wheel controlled

car light piloting system which

automatically turns the lights of the motor car to coincide the projection of the lights with the
steering direction of the motor car .The present invention comprises an electric contact
mechanism consisted of electric brushes and metal contacts disposed around the steering
column of the steering wheel of a motor car ,a motor drive consisted of at least one servo
motor, a control circuit connected

between the motor drive and the electric contact

mechanism to control the revolving direction to the turning direction of the steering wheel,
and a transmission mechanism consisted of at least one hydraulic cylinder systems and
controlled by the motor drive to turned the light of motor car causing them to coincide with
the steering direction of the motor car .

10

Fig.2.1 Transmission mecchanism

Ken chi Nishimura [3], suggested that the apparatus for automatically adjusting a direction
of a light axis of a vehicle headlight includes a steering angle sensor detecting a steering
angle of a steering wheel of a vehicle and a swivel control unit performing swivel control by
which the direction of the light axis of the vehicle headlight is adjusted to the target direction
in accordance with the steering angle detected by the steering angle sensor. The swivel
control unit varies sensitivity or responsiveness of the swivel control depending on a value of
the steering angle detected by the steering angle sensor.
The direction of the optical axis of each swivel light is adjusted based on a swivel
control angle obtained upon application of the filter. A filter is changed to change a response
in swivel adjustment of a direction of an optical axis of each swivel light based on a steering
angle variation of a steering angle of a steering wheel measured with a steering angle sensor.
A weaker filter is selected if the steering wheel is quickly steered and a stronger filter is
selected if the steering wheel is slowly steered. By this filtering operation the direction of the
optical axis of each swivel light is adjusted in response to the steering operation of the
steering wheel without causing an uncomfortable feeling to a driver.
Hiroaki okuchi [4], proposed automatic optical-axis adjusting device for automatically
adjusting direction of optical axes of front lights with respect to steering angle of steering
wheel An electronic control for automobile headlight utilizing a spherical sensor comprised
of a metal ball surrounding by a fluid encapsulated in a spherical sensor which is connected
to the spherical sensor system. Computer controlled unit is positioned on and close behind the
headlight so that the metal ball cooperate with sensor within the spherical sensor system to
make the headlight go so as to follow the car during turns .
Heather Steiner brown [5], electric control for automobile head lights Output of each sensor
arrangement is supplied to an ECU through a communication bus line. A value of a turning
radius of a vehicle which is used for adjusting direction of optical axes of swivel lights is
11

computed based on the output of each sensor arrangement is obtained. An optical axis control
angle is computed based on the normal computed values and is used to drive actuators to
adjust direction of the optical axes of the swivel lights.
Masanori kondo [6], suggested the automatic optical axis adjusting device for automatically
adjusting direction of optical axis of from lights headlight control apparatus and method
controls an irradiation direction of a headlight. This apparatus uses a navigation based swivel
angle calculated based upon the shape of a road in a navigation based control period and a
steering based swivel angle calculated based upon a steering angle in a steering based control
period. When the control period to the steering based control period this apparatus uses a
value between the navigation based swivel angle and the steering based swivel angle as a
present control swivel angle for controlling the irradiation direction of the headlight.

12

CHAPTER 3

PROBLEM DEFINATION
The vehicle moves on a circular path when driver turn the steering wheel. The circular path is
defined by the movement of the wheel and angle position of the front wheel. when driver
steer the wheel could not able to the turn headlight in the direction of the road turn, so driver
will not judge the proper turn of the road which causes accident in sharp turning.
The lights of a motor car are commonly fixed in position. as shown in fig.3.1, the projection
of light d of the light l of the motor car m is the constantly maintained in line with the motor
car m. when steering wheel the motor car m is turned in the either direction, the body of the
motor car m is not synchronously turned in the same direction, i.e. the body of the motor car
m moved to follow the steering direction at the time delay. Because the driver wheel directs
the eye towards their desired direction before the motor car M is turned to coincide, a blind
angle G exists out of the projection of the light of the lights L of the motor car M within the
drivers view angle. Therefore, a traffic accident may happen while one is changing the
steering direction of the motor car.

13

Fig. 3.1 Projection Of Light

14

CHAPTER 4
METHEDOLOGY
For finding solution we have to study about-

Steering System
Primary function of the steering system is to achieve angular motion
of the front wheels to negotiate a turn. This is done through linkage and steering gear which
convert the rotary motion of the steering wheel into angular motion of the front road wheels.
Secondary function of steering system is:1. To provide directional stability of the vehicle when going straight ahead.
2. To provide perfect steering condition, i.e., perfect rolling motion of the road wheels at all
time.
3. To facilitate straight ahead recovery after completing a turn.
4. To minimize tyre wear.

15

Fig.4.1 Steering System

16

The parts of steering system are:Steering - Steering basically consists of:A. Steering linkage
B. Steering gear

A. Steering Linkage-it depend upon the type of vehicle, wither it is a car which has
independent front suspension. Each of these linkages will now be described.
a) Steering Linkage for Vehicle with Rigid Axle Front Suspension
The drop arm ( also called pitman arm)is rigidly connected to the cross
shaft of the steering gear at its lower end, while its lower end connected to the link rod
through the ball joint, and the other end of the link rod is connected to the link arm through a
ball joint. Attached rigidly to the other end of the link rod arm is the stub axle on which the
rod wheel is mounted. Each stub axle has a forged track rod arm rigidly bolted to the wheel
axis. The other end of the track rod arm connected to the track rod by means of ball joints.
The design of these ball joints is such that the expanding spring compensates for wear or
misses adjustment. An adjuster is also provided in the track rod to change its length for
adjusting wheel alignment.

Fig 4.2 Steering Linkage for Vehicle with Rigid Axle Front Suspension

17

(b) Steering Linkage For Vehicle With Independent Front System

In case of conventional rigid axle suspension, the main axle beam ensures the
movement of stub axle in the horizontal plane only. In these therefore, there is no vertical
deflection of the suspension and hence there is no change in effective track rod length.
However, in the case of independent suspension, the two stub axle can move up or down
independent of each other due to which distance between balls joints ends of the two track
and arms is continuously varying. On account of this a single track rod as in conventional
system cant be used.
In this three piece track rod is used, the center portion being called the relay rod,
which is connected at one end to an idler arm supported on body structure and to the drop
arm of the steering gear at the other end through ball joint. Relay rod is restricted to move
only in horizontal plane only. Movement of vertical plane provided by the outer portion.

Fig 4.3 Steering linkage for vehicle with independent front suspension

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B. Steering Gear- The steering gear convert the turning motion of the steering wheel into the
to and fro motion of the link rod of the steering linkage. The working of the other types is
also similar.

a) Worm & Wheel Steering Gear

The movement of the steering wheel turns the worm, which is turn drives
the worm wheel. Attached to the wheel spindle rigidly is drop arm, so that a rotation of the
steering wheel corresponds to a linear motion of the drop arm end, which is connected to the
link rod.

Fig 4.4 Worm and wheel steering gear

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b) Rack And Pinion Steering Gear

The rotary motion of the steering wheel is transmitted to the pinion of the steering gear
through universal joints. The pinion is in mesh with a rack. The circular motion of the pinion
is transferred into the linear rack movement which is further relayed through the ball joints
and tie rods to the stub axles for the wheel to be steered.

Fig 4.5 Rack and pinion steering gear

2 . Front Axle
Conventionally the front axle is a dead axle. However these days
this is

true of heavy vehicle only. For four wheel drive vehicle and most of the cars, it is

a live axle. In case of a dead axle, the front axle beam is usually a drop forging of steel. The
axle has to take bending loads due to weight of the vehicle and also torque loads due to the
braking of the wheels. For this reason, front axle is made of I- section in the central portion,
while the ends are made either circular or elliptical, A downward sweep is given to the center
portion to keep a low chassis height.

20

The main axle beam is connected to the stub axle by means of the king pin, the
stub axle connection consist of stub axle, king pin, front axle, tie rod.
3 . Headlight Unit
Headlight consists of a combined aluminized metal reflector and front lens
assembly. The bulb is fitted in a sleeve attached to the rear of the reflector to ensure preset
positioning of the filaments with respect to the focal point of the reflector. The bulb is filled
with some inert gas such as argon or nitrogen at some pressure which rises the vaporization
temperature of filament material.
The different types of headlight units are use such as
Sealed beam headlight unit- In this the aluminized glass reflector and the glass lens
are fused to form a single unit inside which is filled some inert gas.
Halogen- quartz headlight units It consist of tungsten filament in the atmosphere of
some halogen element such as chlorine, bromine or iodine.
High intensity discharge(HID) headlight unit This HID light do not have any
filament rather, there are two electrode and light is produced as the high voltage
bridges the air gap between this electrodes, producing an arc in inert gas atmosphere.

Fig.4.6 Conventional Headlight Arrangement

21

Rack and pinion gear

A rack and pinion is a type of liner actuator that comprises a pair
of gears which convert rotational motion into linear motion. A circular gear called
"the pinion" engages teeth on a linear "gear" bar called "the rack"; rotational motion
applied to the pinion causes the rack to move, thereby translating the rotational
motion of the pinion into the linear motion of the rack.
Pinion is a common spur gear and Rack is a portion of spur gear with
an infinite radius.

Fig .4.7 Rack and pinion gear

SPUR GEAR
Spur gears or straight-cut gears are the simplest type of gear. They consist of
a cylinder or disk with the teeth projecting radially, and although they are not straight-sided
in form, the edge of each tooth is straight and aligned parallel to the axis of rotation. These
gears can be meshed together correctly only if they are fitted to parallel shafts.

Fig .4.8 Spur gear

22

BELT DRIVE SYSTEM

A system consisting of a belt and at least two fixed pulleys that transmit
motion from one pulley to the other. In a two pulley system, belts are looped over pulleys.

Fig.4.8 Belt drive system

BELT
A loop of flexible material used in a belt drive system to transmit motion. Belts are
made of various materials and come in different types, such as flat belts, round belts, and Vbelts.
FLAT BELT
A belt consisting of a flat loop of material used to transmit motion between two
pulleys. Flat belts can be made of various materials, such as rubber, canvas, plastic, or
flexible metals.

23

FIXED PULLEY
A device consisting of a wheel rigidly fixed to a shaft that is used in a belt drive
system to transmit energy.

PULLEY
A circular device that is used as a pair in belt drive systems to transmit motion.

Fig.4.9 Cast iron pulley

Diameter of bigger pulley = 5 inches

Diameter of smaller pulley = 2 inches

24

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CHAPTER 5
RESULT

From above study we come to know that this method can be used for swiveling
headlight according with steering movement such as methods like optical sensor, light
piloting system, adaptive control system etc. Moveable headlight with above method can be
used but they are costly and require higher maintenances.
We reach to a result that for this purpose we can use a
rack and pinion arrangement which give drive to the optical axes on which headlight are
mounted so when a tie rod arms are moved with steering arm that give predefined motion to
the wheel as well as headlights.

32

CHAPTER 6
CONCULUSION

At night time, driving a vehicle in hilly areas can be quite challenging. No

illumination on turns due to fixed headlamps makes it difficult to accommodate for
sharp turns. Lack of visibility at turns in narrow roads can prove to be fatal.

SCOPE OF FURTHER WORK

To find alternative methods of headlight system which may provide more safety while
driving.

33

BIBLIOGRAPHY
[1] Amit Sarda The steering system in automobile journal 1993 page no. 1322 to 253
[2] Books
Dr. Kirpal Singh
Dr. R.B Gupta
Prof. A. Z. Tirkel
Wikipedia

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