Abstract:
A motorized adjuster ( 30 ) is used for adjusting the aim of a lamp. The adjuster has a housing ( 32 ) and a motor ( 36 ). An output shaft ( 38 ) passes through the housing and is operably connected to the motor. A ball stud ( 60 ) is moved by actuation of the motor and may also be moved by manual operation ( 41 ). A clutching feature may be included to prevent damage due to over adjustment attempts.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates generally to adjusters which are used to adjust the aim of a vehicle lamp. Specifically, this invention relates to a motorized lamp adjuster for adjusting the aim of a vehicle lamp using motorized or manual operation. 
   Vehicles such as automobiles typically have several lamps including head lamps and fog lamps. These lamps typically include a reflector sealed to a lens with a bulb therein. These lamps are securely fit into mounting brackets. The lamps are usually pivotally engaged to the mounting bracket at a plurality of points. The mounting brackets are attached to the vehicle. Together, a lamp and a mounting bracket form a complete lamp assembly. Once the lamp assembly has been manufactured and installed into a vehicle, the aim of the lamp must be adjusted to the proper aim. As a result of accidents, maintenance, and normal vibrations and wear, the aim of the lamp must be occasionally adjusted during the lifetime of the vehicle. 
   One method of adjusting the aim of the lamp involves using an adjuster. The adjuster may be formed as part of the mounting bracket or may be a separate part that communicates with both the lamp and the mounting bracket. One known type of adjuster comprises a housing and an output shaft extending there from. The output shaft is engaged to the lamp. Actuation or operation of the adjuster causes the output shaft to move with respect to the lamp assembly. Such movement causes the lamp to pivot with respect to the mounting bracket, thereby adjusting the aim of the lamp. 
   One example of this type of adjuster, such as the one disclosed in U.S. Pat. No. 6,257,747 to Burton, requires manual operation. The housing of the adjuster has an opening and a gear positioned inside the housing. The gear is functionally engaged to the output shaft. A driver is inserted into the opening and interacts with the gear. Actuation of the driver results in rotation of the gear and engaged output shaft. The gear translates actuation of the driver into movement of the output shaft. Numerous variations and improvements exist on this concept. 
   A manual adjuster has limited applicability. Many countries require a driver to be able to adjust the aim of a vehicle&#39;s lamps from inside the cabin. Additionally, certain vehicles are now offering lamps that track and illuminate the direction of the vehicle or that adjust the aim of the lamp to compensate for the pitch of the road or weight of the vehicle (i.e. driving on hilly terrain or with a heavy load in the vehicle). The aim of the lamp is automatically adjusted as the steering wheel is turned or as a result of the relative pitch of the suspension. A computer coordinates the degree of turn of the steering wheel, the speed of the vehicle, and/or the pitch of the suspension with the aim of the lamps. This coordination requires a high degree of precision. A driver cannot safely turn a steering wheel and manually adjust the aim of the vehicle&#39;s lamps at the same time. 
   A number of motorized lamp adjusters have been developed to provide improved functionality. Many of these adjusters provide for both manual and motorized operation. In practice, the adjusters are manually operated to aim the lamp during manufacture, maintenance, and repair of the vehicle. The adjusters rely on motorized operation to aim the lamp while the vehicle is on the road. These adjusters can be connected to control units that provide for automatic adjustments while the vehicle is driven. Examples of such adjusters are disclosed in U.S. Pat. No. 5,394,318 to Komachi; U.S. Pat. No. 5,673,991 to Eickhoff et al.; and U.S. Pat. No. 6,012,829 to Natchoo. These adjusters all use an electric motor to longitudinally move a output shaft. The motors are offset from the output shaft and located inside the adjuster housing. These adjusters rely on a series of gears, speed reducers, circuits, potentiometers, and transmissions to translate the power generated by the motor into longitudinal movement of the output shaft. As such, these adjusters employ a series of parts. Each part must be separately manufactured. The parts are then assembled inside the housing to form the adjuster. Using multiple parts increases the potential for malfunction, breakage and general wearing of the adjuster. Further, using a series of parts results in a larger housing and thus a larger adjuster. Such an adjuster requires more space in a vehicle, thereby affecting the overall design and manufacture of the vehicle and making the overall cost of both the adjuster and the vehicle more expensive. 
   Accordingly, a need exists for an improved motorized lamp adjuster that solves these and other deficiencies in the prior art. Of course, the present invention may be used in a multitude of situations where similar performance capabilities are required. 
   SUMMARY OF THE INVENTION 
   The present invention provides a motorized lamp adjuster that is cost-effective, provides improved functionality, and which solves certain of the problems raised or not solved by existing designs. 
   The adjuster includes a housing, a motor, and an output shaft. In one embodiment, the output shaft passes through the housing and the motor and is functionally engaged by the motor such that operation of the motor causes axial movement of the output shaft. An anti-rotation gear is ideally positioned inside the housing such that the output shaft passes through and is functionally engaged by the anti-rotation gear. The anti-rotation gear is used to operate the adjuster manually. The anti-rotation gear also prevents the output shaft from rotating when the motor is in use. The anti-rotation gear is positioned in the housing such that the anti-rotation gear is biased against rotation. The output shaft preferably has a rotation point and the anti-rotation gear is configured to geometrically mate with the rotation point such that manual rotation of the anti-rotation gear causes the output shaft to rotate. The adjuster is operated manually by inserting a driver into the housing and rotating the driver. The driver can be inserted through a driver input locator in the housing. Once inserted, the driver functionally engages the output shaft through the anti-rotation gear such that rotation of the driver causes the output shaft to rotate and move axially. The driver may alternatively be included as part of the adjuster assembly. 
   In another embodiment, a drive gear is positioned within the housing such that the output shaft passes through the drive gear but does not engage the drive gear. Instead, the drive gear engages a ball insert that is functionally engaged to the output shaft. Motorized operation of the adjuster using the motor causes the output shaft to move axially, which in turn causes the ball insert to move axially and effectuate an adjustment to the aim of the lamp. To manually operate the adjuster, a driver engages the drive gear to rotate the drive gear, which rotates the ball insert and causes the ball insert to move axially with respect to the output shaft and effectuate an adjustment to the aim of the lamp. The output shaft does not rotate or move axially during manual operation. In another embodiment, the functional engagement between the ball insert and the output shaft includes a clutching mechanism. 
   The present invention may also include a lamp assembly. The lamp assembly has a mounting bracket, a lamp pivotally engaged within the mounting bracket, and an adjuster in accordance with any embodiment of the present invention. The adjuster is securely engaged to the mounting bracket and functionally engaged to the lamp. Further, a power source and/or control unit is electrically connected to the motor if motorized adjustment is desired. 
   While one possible application of the present invention is in connection with a vehicle lamp, many other applications are possible and references to use in connection with a vehicle lamp should not be deemed to limit the uses of the present invention. The terms “lamp,” “mounting bracket,” “lamp assembly,” “output shaft,” “housing” or “ball” as used herein should not be interpreted as being limited to specific forms, shapes, or compositions. Rather, the parts may have a wide variety of shapes and forms and may be composed of a wide variety of materials. These and other objects and advantages of the present invention will become apparent from the detailed description, claims, and accompanying drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a motorized adjuster in accordance with one embodiment of the present invention; 
       FIG. 2  is an exploded view of the motorized adjuster of  FIG. 1 ; 
       FIG. 3  is an exploded view of the motorized adjuster of  FIG. 1 ; 
       FIG. 4  is a perspective view of the motorized adjuster of  FIG. 1 , shown with the housing removed and the motor and anti-rotation gear in partial cross-section; 
       FIG. 5  is a partial cross sectional view of the motorized adjuster of  FIG. 1  taken along plane  5 - 5  with a lamp and mounting bracket shown in phantom; 
       FIG. 6  is a partial cross sectional view of the motorized adjuster of  FIG. 1  taken along plane  5 - 5  with a lamp and mounting bracket shown in phantom, and illustrating motorized operation of the adjuster; 
       FIG. 7  is a partial cross sectional view of the motorized adjuster of  FIG. 5  taken along the plane  7 - 7  in  FIG. 5 ; 
       FIG. 8  is a partial cross sectional view of the motorized adjuster of  FIG. 7  taken along the plane  8 - 8  in  FIG. 7 ; 
       FIG. 9  is a partial cross sectional view of the motorized adjuster of  FIG. 3  taken along the plane  9 - 9  in  FIG. 3 ; 
       FIG. 10  is a front view of the motorized adjuster of  FIG. 1 ; 
       FIG. 11  is a partial cross sectional view of a lamp assembly in accordance with one embodiment of the present invention; 
       FIG. 12  is a cross sectional view of the motorized adjuster of  FIG. 3  taken along the plane  12 - 12  in  FIG. 3 ; 
       FIG. 13  is a partial cross sectional view of a lamp assembly in accordance with one embodiment of the present invention; 
       FIG. 14  is a perspective view of a motorized adjuster in accordance with another embodiment of the present invention; 
       FIG. 15  is an exploded view of the motorized adjuster of  FIG. 14 ; 
       FIG. 16  is an exploded view of the motorized adjuster of  FIG. 14 ; 
       FIG. 17  is a perspective view of the motorized adjuster of  FIG. 14 , shown with the housing removed and the motor and drive gear in partial cross-section; 
       FIG. 18  is a partial cross sectional view of the motorized adjuster of  FIG. 14  taken along plane  18 - 18  with a lamp and mounting bracket shown in phantom; 
       FIG. 19  is a partial cross sectional view of the motorized adjuster of  FIG. 14  taken along plane  18 - 18  with a lamp and mounting bracket shown in phantom, and illustrating motorized operation of the adjuster; 
       FIG. 20  is a partial cross sectional view of the motorized adjuster of  FIG. 14  taken along plane  18 - 18  with a lamp and mounting bracket shown in phantom, and illustrating manual operation of the adjuster; 
       FIG. 21  is a partial cross sectional view of the motorized adjuster of  FIG. 18  taken along the plane  21 - 21  in  FIG. 18 ; 
       FIG. 22  is a partial cross sectional view of the motorized adjuster of  FIG. 21  taken along the plane  22 - 22  in  FIG. 21 ; 
       FIG. 23  is a front view of the motorized adjuster of  FIG. 14 ; 
       FIG. 24  is a cross-sectional view of the motorized adjuster of  FIG. 18  taken along plane  24 - 24  in  FIG. 18 ; 
       FIG. 25  is a partial cross sectional view of a lamp assembly in accordance with one embodiment of the present invention; 
       FIG. 26  is a partial cross sectional view of a lamp assembly in accordance with one embodiment of the present invention; 
       FIG. 27  is a perspective view of a motorized adjuster in accordance with another embodiment of the present invention; 
       FIG. 28  is a partial cross sectional view of the motorized adjuster of  FIG. 27  taken along line  28 - 28  with a lamp and mounting bracket shown in phantom; 
       FIG. 29  is a perspective view of the motorized adjuster of  FIG. 27 , shown with the housing removed and the motor and drive gear in partial cross-section; 
       FIG. 30  is a cross-sectional view of the motorized adjuster of  FIG. 28  taken along plane  30 - 30  in  FIG. 28 ; and, 
       FIG. 31  is a cross-sectional view of the motorized adjuster of  FIG. 28  taken along plane  31 - 31  in  FIG. 28 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Illustrative embodiments of a motorized lamp adjuster (identified generally as  30 ) in accordance with the present invention are shown in  FIGS. 1 through 31 . While the invention may be susceptible to embodiment in different forms, there are shown in the drawings, and are described herein in detail, certain illustrative embodiments with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to those embodiments illustrated and described herein. Additionally, features illustrated and described with respect to one embodiment could be used in connection with other embodiments. 
   As shown in  FIGS. 11 ,  13 ,  25  and  26 , the adjuster  30  is generally used in connection with a vehicle lamp and forms part of the lamp assembly  20 . A lamp assembly  20  typically includes a lamp  21  and a mounting bracket  28 . The lamp  21  has a reflector  24  sealed to or otherwise enclosed by a lens  22 , and a bulb  26  disposed between the reflector  24  and the lens  22 . As shown in  FIGS. 11 and 25 , the lamp  21  can be pivotally engaged to the mounting bracket  28 . As shown in  FIGS. 13 and 27 , the mounting bracket  28  could form a portion of the lamp  21 . In  FIGS. 13 and 26 , the reflector  24  is mounted to the mounting bracket via a pivot post  100 . The adjuster  30  securely engages the mounting bracket  28  and functionally engages the lamp  21 . The adjuster  30  may engage any portion of the lamp  21 , such as the reflector  24  as shown in  FIGS. 11 ,  13 ,  25  and  26 . 
   Common to all embodiments shown in  FIGS. 1-31  is a housing  32  which engages the mounting bracket  28 . The housing  32  can be constructed from any suitable rigid material and manufactured by any suitable technique. It has been found feasible to manufacture the housing from injection molded plastic. As shown in  FIGS. 1 ,  5 ,  6 ,  14  and  18 - 20 , the housing  32  has a nose  64  and a body  66 . The nose  64  engages the mounting bracket  28 . The nose  64  may be securely engaged to the mounting bracket  28  via sliding engagement, snap fit, screw in, or other method. Examples of how an adjuster can be mounted to a bracket are shown in the following U.S. Patents to Burton, the disclosures of which are incorporated herein by reference: U.S. Pat. Nos. 6,474,850; 6,257,747; 6,050,712; 6,042,254; and 5,707,133. In addition, the adjuster  30  may be mounted or securely engaged to the mounting bracket  28  via sliding engagement, snap fit, screw in, quarter-turn fashion, or other method. As shown in  FIGS. 11 and 25 , the housing  32  can be engaged to the mounting bracket  28  in a quarter-turn fashion. The mounting bracket  28  has an opening configured to mate with the nose  64 . The nose  64  is inserted into the opening and turned, thereby securing the housing  32  to the mounting bracket  28 . The nose  64  is ideally turned sixty degrees, however, turns of other degrees would also be possible. As shown in  FIGS. 1 ,  11 ,  14  and  25 , an O-ring or gasket  62  is positioned on the nose  64  and against the body  66 . Engagement of the nose  64  with the mounting bracket  28  creates a seal between the body  66 , the O-ring or gasket  62 , and the mounting bracket  28 . Preferably this engagement creates a facial seal between the body  66  and the O-ring  62  and between the O-ring  62  and the mounting bracket  28 . It is also possible to integrally form the housing  32  of the adjuster  30  as part of the mounting bracket  28  or other structural parts of the lamp assembly  20 . 
   Also common to all embodiments shown in  FIGS. 1-31  is a motor  36  having a rotor  44 . The motor  36  is ideally electrically connected to a power supply via a control cord  91  to a connector  92 . The power supply is preferably the battery of the vehicle. As shown in  FIGS. 11 ,  13 ,  25  and  26 , the motor  36  is electrically connected to a control unit  90  by control cord  91 . The control unit  90  may be an electronic control unit (ECU), computer, electrical signal transmitter, or a switch. Several types of motors could be used, including, but not limited to, a stepper motor such as the NMB Stepper Motor PL35L-02-USNJA, or a linear motor such as the MPL35A-24 linear motor manufactured by Taishan Siang. Although the drawings show the motor  36  and output shaft  38  as separate parts, it is of course also possible to purchase a pre-assembled motor unit in which the output shaft  38  has already been assembled into the motor  36 . 
   One embodiment of the adjuster  3   0  of the present invention is illustrated in  FIGS. 1-13 . As shown in  FIGS. 2 and 3 , the adjuster  30  includes a number of parts. The adjuster  30  includes a housing  32  and a motor  36 . The motor  36 is positioned in, or in contact with, the housing  32 . A output shaft  38  is positioned in and extends through the housing  32  and the motor  36 . The output shaft  38  interacts with and is functionally engaged at one end to the lamp  21 , as shown in  FIGS. 11 and 13 , and engaged to the motor  36  at the other end. An anti-rotation gear  40  is positioned inside the housing  32 . The output shaft  38  is inserted into and through the anti-rotation gear  40 . 
   As shown in  FIGS. 2 ,  3 ,  5 , and  6 , the body  66  has a receptor  68  which extends into the nose  64 , a recess  70 , and a driver input locator  72 . An anti-rotation gear  40  is positioned inside the body  66  of the housing  32 . The anti-rotation gear  40  has an extension  74  and a head  76  with a plurality of gear teeth  48  thereon. In  FIGS. 2 and 3 , the gear teeth  48  are oriented toward the extension  74 . Alternatively, the gear teeth  48  may be oriented away from the extension  74 . Preferably, the anti-rotation gear  40  is constructed from a single piece of plastic, but other configurations are possible. In positioning the anti-rotation gear  40  inside the body  66 , the extension  74  is inserted into the receptor  68 . As shown in  FIGS. 5 and 6 , the extension  74  preferably snap fits into the receptor  68 . Inserting the extension  74  into the receptor  68  causes the head  76  to abut the recess  70 . As shown in  FIG. 3 , the recess  70  has at least one flex point  56 . The flex point  56  may take a variety of forms. For example, it has been found effective for the recess to have three flex points  56  as shown in  FIG. 7 , but other numbers of flex points  56  may be used. The flex point  56  interacts with and functionally engages the anti-rotation gear  40 . As shown in  FIG. 8 , the flex point  56  interacts with the gear teeth  48 . The flex point  56  allows the anti-rotation gear  40  to rotate when the adjuster  30  is manually operated via the driver  41 , but prevents the anti-rotation gear  40  from rotating when the adjuster  30  is operated via the motor  36 . Alternatively, the interference between the anti-rotation gear  40  and the housing  32 , or other interferences within the device, may be great enough to prevent rotation of the anti-rotation gear  40  when the adjuster  30  is operated via the motor  36 . In such an embodiment, the adjuster  30  does not have any flex points  56  positioned therein. 
   As shown in  FIG. 7 , the adjuster  30  is manually operated by actuating a driver  41  inserted into the driver input locator  72  (see, e.g.,  FIG. 2 ). The driver  41  can be locked in place by a driver retainer  94  positioned in the driver input locator  72 . The driver  41  preferably has a groove  95  positioned thereon that snap fits into the driver retainer  94 . The driver  41  functionally engages the gear teeth  48  of the anti-rotation gear  40 . The gear teeth  48  are configured to functionally interact and geometrically mate with the driver  41 , preferably with driver teeth  50  as shown. Actuating the driver  41  causes the anti-rotation gear  40  to rotate. Ideally, the head  52  of the driver  41  can be engaged and turned by a tool such as a wrench, screwdriver, or TORX® driver. Alternatively, the driver  41  itself can be a tool such as a flat head, Phillips head, or a TORX® driver, depending on the configuration of the gear teeth  48 . 
   As shown in  FIGS. 2-6 , the output shaft  38  is inserted through the anti-rotation gear  40  and extends past the nose  64  of the housing  32 . The output shaft  38  has a lamp end  78 , at least one rotation point  46 , and a driver end  82 . The lamp end  78  of the output shaft  38  is engaged to the lamp  21 , as shown in  FIGS. 11 and 13 . The lamp end  78  is engaged to the reflector  24 , but other points of attachment to the lamp  21  may be used. The lamp end  78  is ideally engaged to the lamp  21  via a ball  60 . The ball  60  can be any material, but it has been found effective for the ball  60  to be constructed of a flexible material such as plastic. Alternatively, the output shaft  38  may be directly engaged to the lamp  21 , engaged to a grommet engaged to the lamp  21 , and/or may include a ball  60  formed as part of the output shaft  38  or any other form of pivoting mechanism. 
   The output shaft  38  is inserted into, passes through, and is in contact with the anti-rotation gear  40 . In  FIGS. 2 and 3 , the output shaft  38  passes through a bearing  42  fit into the head  76  of the anti-rotation gear  40 . The bearing  42  reduces the amount of wear on the anti-rotation gear  40  and the rotor  44  due to the interaction there between. In  FIGS. 2 and 3 , the output shaft  38  passes through an additional bearing  96  positioned between the rotor  44  and the stator or drive unit  45 . The bearings  42  and/or  96  are preferably manufactured from a low friction material such as stainless steel. As shown in  FIG. 4 , the output shaft  38  has at least one anti-rotation point  46 . The anti-rotation point  46  can take a variety of forms, shapes, and numbers depending on the exact configuration and desired characteristics of the adjuster  30 . The extension  74  of the anti-rotation gear  40  is configured to geometrically mate with the output shaft  38  and the rotation point  46 . In  FIGS. 2 and 3 , the anti-rotation point  46  is a small bolt inserted through the output shaft  38  at an angle, preferably ninety degrees, relative to the axis of the output shaft  38 . Referring to  FIGS. 9 and 12 , the extension  74  of the anti-rotation gear  40  has an interior  84  with a central round opening  85 . The output shaft  38  inserts through the central round opening  85 . The rotation point  46  functionally engages the anti-rotation gear  40 . Rotation of the anti-rotation gear  40  causes the interior  84  of the extension  74  to come into contact with the rotation point  46 . The interior  84  exerts a force on the rotation point  46 , thus rotating the output shaft  38 . Therefore as shown in  FIG. 7 , the anti-rotation gear  40  and output shaft  38  rotate as a single unit. 
   As shown in  FIGS. 5 and 6 , the driver end  82  of the output shaft  38  is inserted in and engaged to the motor  36 . The motor  36  includes a rotor  44  and a drive unit  45 . As shown in  FIG. 2 , the drive unit  45  has a stator  93  and a connector  92 . As shown in  FIGS. 2 ,  5 , and  6 , the rotor  44  is positioned inside the drive unit  45 . The driver end  82  and the rotor  44  are threaded together. The driver end  82  is threaded into the rotor  44 . 
   The adjuster  30  can be operated either manually or via the motor  36 . In the embodiment shown in  FIGS. 1-13 , the adjuster  30  adjusts the aim of the lamp  21  via axial movement of the output shaft  38 . As shown in  FIG. 11 , the housing  32  of the adjuster  30  is engaged to the mounting bracket  28 . The output shaft  38  of the adjuster  30  is engaged to the lamp  21 , preferably via ball  60 . As shown in  FIGS. 5 and 6 , operation of the adjuster  30  causes the output shaft  38  to move axially. Such movement results in pivoting of the lamp  21 , thereby adjusting the aim of the lamp  21 . Manual operation is accomplished by actuating the driver  41  positioned in the body  66  of the housing  32 . Actuating the driver  41  results in rotation of the anti-rotation gear  40  and the output shaft  38 . Rotation of the output shaft  38  causes the output shaft  38  to move along its axis, as it is threaded through the rotor  44  that is fixed during manual operation. Rotation of the output shaft  38  in one direction causes the output shaft  38  to extend towards the lamp  21 . Rotation in the opposite direction causes the output shaft  38  to retract from the lamp  21 . As such, rotation of the output shaft  38  results in axial movement of the output shaft  38 . Motorized operation is accomplished by actuation of the motor  36  engaged to the driver end  82  of the output shaft  38 . Actuation of the motor  36  causes the rotor  44  to rotate therein. As discussed, the driver end  82  and the rotor  44  are threaded together. The anti-rotation gear  40  prevents the output shaft  38  from rotating during motorized operation of the adjuster  30 . Therefore, rotation of the threaded rotor  44  about the threaded portion of the output shaft  38  results in the output shaft  38  moving along its axis. 
   Another embodiment of the adjuster  30  of the present invention is illustrated in  FIGS. 14-31 . The adjuster  30  shown in  FIGS. 14-31  includes a number of the same parts as the embodiment of  FIGS. 1-13 , and unless described otherwise herein, the common parts perform the same functions and can take the same form in each embodiment. As shown in  FIGS. 14-17 , the adjuster includes a housing  32 , a motor  36 , and an output shaft  38  inserted through the housing  32  and the motor  36 . The housing  32  may be a two-part housing as shown, including a back housing portion  33  and a front housing portion  34 . Other housing configurations are certainly possible, however, including a configuration such as the one-piece housing used in the embodiment shown in  FIGS. 1-13  or a two-part housing with a simple cover. The front housing portion  34  includes a body  66 , a nose  64 , and a driver input locator  72 . The motor  36  is positioned in, or in engagement with, the housing  32 . The motor  36  includes a rotor  44 , which is functionally engaged with the output shaft  38  using a threaded connection. The motor  36  also includes a front flange  43 . An anti-rotation point  46  is located on the output shaft  38 . The output shaft  38  is inserted into and through the motor  36  such that anti-rotation point  46  is disposed within a channel  47  within the motor flange  43 . The disposition of the anti-rotation point  46  within the channel  47  allows the output shaft  38  to traverse axially over a distance equal to the length of the channel  47 , but prevents the output shaft  38  from rotating. The axial movement of the output shaft  38  is illustrated best in  FIGS. 18 and 19 . In  FIG. 18 , the anti-rotation point  46  is located near the middle of channel  47 , and, after axial movement of the output shaft  38  caused by motorized operation of the adjuster  30 , the anti-rotation point  46  is shown near the front end of the channel  47  in  FIG. 19 . 
   Referring again to  FIGS. 14-17 , the output shaft  38  is inserted into and through a drive gear  39  positioned at least partially inside the housing  32 . The drive gear  39  is preferably constructed from a single piece of plastic, but other configurations and materials could be used. The output shaft  38  has a driver end  82  that engages the motor  36  and a lamp end  78  that engages the lamp  21  via ball insert  59 . The drive gear  39  has an extension  75  and a head  77  having gear teeth  49  formed on one side thereof.  FIGS. 15 and 16  show the gear teeth  49  formed on the extension side of the head  77  and thus oriented toward the extension  75 , but the gear teeth  49  could be formed on the other side of the head  77  and oriented away from the extension  75 . The ball insert  59  includes a ball  60  and an extension  61 . The drive gear  39  functionally engages the ball insert  59 . To accomplish this, the drive gear extension  75  can include longitudinal splines  102  that engage the ball insert extension  61 .  FIGS. 14-26  show a drive gear extension  75  having external splines  102  that engage an internal hex geometry of the ball insert  61 , as is best shown in  FIG. 24 .  FIGS. 27-31  show a drive gear extension  75  having internal splines  102  that engage clutching tabs  104  formed on the exterior of the ball insert extension  61 . Other engagement methods could also be employed. 
   A driver  41  having a head  52  and drive teeth  50  is inserted into the driver input locator  72  such that teeth  50  engage the gear teeth  49  of the drive gear  39 , as can best be seen in  FIGS. 18-21  and  28 . As illustrated therein, the driver  41  is used to manually operate the adjuster  30 . Manual rotation of the driver  41  effects movement of the ball insert  59 . Rotation of the driver  41  causes the drive gear  39  to rotate, which in turn causes the ball insert  59  to rotate. The ball insert  59  is engaged with the output shaft  38  using a threaded connection. As the ball insert  59  rotates, the ball insert  59  moves axially with respect to the output shaft  38 , which is fixed during manual operation of the adjuster. Keeping the output shaft  38  in a fixed position during manual operation of the adjuster  30  allows the output shaft  38  to stay in its nominal position during manual operation of the adjuster. Rotating the drive gear  39  in one direction will effect forward axial movement of the ball insert  59 , and rotating the drive gear  39  in the other direction will effect backward axial movement of the ball insert  59  as illustrated in  FIG. 20 . As shown in  FIGS. 21 and 22 , at least one flex point  56  may be used to ensure that the drive gear  39  cannot rotate unless enough torque is applied to the driver  41  to overcome the resistance imposed on the gear teeth  49  by the flex point  56 . The interference between the drive gear  39  and the housing  32  or other interferences within the device could also be great enough to prevent this unwanted rotation of the driver  41  and drive gear  39  without the use of any flex points  56 . 
   If desired for a particular application, clutching tabs  104 , as shown in  FIGS. 27-31 , can be used to prevent the application of excessive torque during manual operation. For example, if a vehicle technician is using the driver  41  to adjust the head lamp, and the ball insert  59  becomes restricted by something the technician cannot see, the technician may continue to apply torque to the driver  41  in an attempt to overcome the restriction. The clutching tabs  104  will, in response to this excessive torque, collapse inwardly and disengage the ball insert  59  from the drive gear  39 , thereby clutching the system to prevent mechanical failures due to the excessive torque applied to the driver  41 . Likewise, if the output shaft  38  is threaded into the ball insert  59  as far as is possible and thus the ball insert  59  cannot move any further in the backward axial direction, the clutching tabs  104  will clutch the system in response to the application of excessive torque. 
   During motorized operation of the adjuster, axial movement of the output shaft  38  effects movement of the ball insert  59  as shown best in  FIGS. 18 and 19 . The rotor  44  of the motor  36  rotates about the output shaft  38 , which is engaged thereto using a threaded connection. Anti-rotation point  46  prevents the output shaft  38  from rotating, and thus the output shaft  38  moves along its axis as the rotor  44  rotates. Ball insert  59  is engaged to the output shaft  38 , and can slide with respect to the drive gear extension  75 . Thus, as the output shaft  38  moves axially, the ball insert  59  moves therewith. Rotation of the rotor  44  in one direction effects forward axial movement of the ball insert  59  as shown in  FIG. 19 , and rotation of the rotor  44  in the other direction effects backward axial movement of the ball insert  59 . 
   The motorized lamp adjuster  30  of the present invention may have other applications aside from use in connection with vehicle lamp assemblies. Although the invention has been herein shown and described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims.