Patent Abstract:
A low profile lighting system for military or other heavy equipment vehicles that includes a high intensity discharge (HID) headlight, and light emitting diode (LED) turn signals and running light. A microprocessor controller is included to interface to the vehicle lighting control system. An electromechanical actuator lifts and holds the light unit in place. The light unit is mounted on a hidden hinge in an armored and signature managed housing. The unique hinge design allows for electromechanical actuation of the lights from a micro-controller. The special hinge enables the external surfaces of the vehicle to be generally planar, and thereby ready to accept further signature management treatments.

Full Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates generally to lighting for combat vehicles and military equipment, and more particularly is a signature managed headlight that is armored and very durable. 
   2. Description of the Prior Art 
   Combat vehicles and other types of military equipment usually have large, bulky lights that, among other drawbacks, can block the drivers&#39; view. The lights are typically incandescent, and were developed in the 1960&#39;s. The bulb elements for the lights are large and round and require careful mounting considerations to survive for even a short time on a combat vehicle due to the delicate filament wire that is required for operation of the incandescent bulbs. Because the incandescent filament bulbs are subject to rapid failure, lights with these bulbs require frequent replacement, and are therefore a logistics burden, particularly for a wartime scenario. 
   In addition, headlight heat from incandescent bulbs creates a thermal signature for the vehicle when the headlights are on. (This often creates a problem when top attack smart munitions are to be employed.) Even when the current art headlights are off, they present multiple visual signature problems. The bulky lights do not permit easy treatments for camouflage or vehicle concealment. Moreover, the current art lights have an internal metalized reflector that can create a visual (sun glint) or radar (reflector) cue even when the lights are off. It is therefore desirable for the lights to be hidden when they are not in use. 
   A typical method of hiding headlights when they are not in use is to mount the headlights on hinges. Automobile popup headlights are known in the art. However, due to the size and weight requirements for military vehicles, signature managed headlights are typically mounted on external hinges. External hinges themselves pose a radar problem for a signature managed headlight design. Accordingly, it is an object of the present invention to provide a signature managed headlight system that utilizes internal hinges and enables the headlights to be stored within the profile of the vehicle body when the headlights are not in use, thereby allowing the easy application of advanced signature treatments to the external surfaces of the vehicle. The improved design also reduces the radar signature of the vehicle. 
   It is a further object of the present invention to provide a light system that does not require incandescent filament bulbs, thereby improving durability and reducing the logistics burden. 
   It is a still further object of the present invention to reduce heat generation and thermal signature. 
   It is another object of the invention to allow light bulb elements to be concealed under shaped plates to prevent sun glint and radar reflections from the mirrored lens of the lighting element. The shaped plates of the integrated armor protection extend the functional life of the lights, and reduce damage from unintended contact (as in a collision) or intentional contact (as while punching a hole into a building in a breaching operation). 
   It is still another object of the present invention to reduce power requirements for the lighting system of a vehicle, while providing greater light output for nighttime operations both on-road and off-road, thereby providing an added measure of operational safety. 
   SUMMARY OF THE INVENTION 
   The present invention is a low profile lighting system for military or other heavy equipment vehicles that includes a high intensity discharge (HID) headlight, and light emitting diode (LED) turn signals and running light. A microprocessor controller is included to interface to the vehicle lighting control system. An electromechanical actuator lifts and holds the light unit in place. The light unit is mounted on a hidden hinge in an armored and signature managed housing. 
   Hinges for collapsible headlights are normally external, so the use of an internal hinge in the present invention is a key to the concealing nature of the design. The unique hinge design, with an external virtual axis of rotation, allows for electromechanical actuation of the lights from a micro-controller. The special hinge enables the external surfaces of the vehicle to be smooth, and thereby ready to accept further signature management treatments. 
   An advantage of the present invention is that the smooth external profile provides a radar signature reduction for the vehicle. Moreover, advanced signature reduction treatments can easily be added over the simple geometry afforded to the exterior profile of the vehicle. 
   Another advantage of the present invention is that the use of non-filament lights leads to improved durability and reduces the logistics burden of repair and replacement. 
   A still further advantage of the present invention is that the thermal signature of the light system of the vehicle is reduced by the use of lights that generate less heat than current art lighting systems. 
   These and other objects and advantages of the present invention will become apparent to those skilled in the art in view of the description of the best presently known mode of carrying out the invention as described herein and as illustrated in the drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a vehicle equipped with the signature managed low profile light system of the present invention. 
       FIG. 2  is a detail view of the light unit mounted on the exterior of the vehicle with the headlight hidden. 
       FIG. 3  is a detail view of the light unit mounted on the exterior of the vehicle with the headlight deployed. 
       FIG. 4  is a side view of the mounted light unit with the exterior side armor broken for viewing. 
       FIG. 5  is a bottom view of the light unit removed from the vehicle. 
       FIG. 6  is an exploded view of the interior hinge of the present invention. 
       FIG. 7  is a front view of the interior hinge. 
       FIG. 8  is a side view of the interior hinge. 
       FIG. 9  is a bottom view of the interior hinge as it would be installed. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention is a signature managed, low profile lighting system for a military or other heavy equipment vehicle. The light unit  10  utilized in the lighting system of the present invention comprises a high intensity discharge (HID) headlight  12  and LED turn signals and running (marker) lights  14  mounted on a light fixture  16 . The light unit  10  further comprises a microprocessor controller that includes interface to the remainder of the vehicle lighting system control system, an electromechanical actuator  20  that lifts and holds the light fixture  16  in position, a hidden interior hinge  22  that allows the light fixture  16  to be retracted, and an armored and signature managed housing  24 . 
   The headlight  12  comprises a high intensity discharge (HID) lamp and a power control assembly that does not include a lighting filament. This is critical to the increased durability of the headlight  12 , as the hot filament in standard headlights is a fragile thing that can and will break under rugged use conditions. The HID headlight  12  is very rugged and can be hard mounted, without causing failure, on trucks, combat vehicles, and other vehicles used in abusive environments. The HID headlight  12  is more efficient and uses 36% less power (35 watts versus 55 watts) than headlights currently used on such vehicle. The reduction in power usage also reduces heat generation, thereby reducing the heat signature of the vehicle. 
   The HID headlight  12  used in the present invention also generates three times the light output (3200 lumens versus quartz halogen of 1000 lumens) of current art headlights. Moreover, the life of the HID headlight  12  is four to five times longer than a typical automotive bulb. (A standard automotive bulb will last 450 to 600 hours, and the HID headlight  12  will last more than 3300 hours. If the HID headlight  12  is not cycled (on &amp; off), they will last indefinitely. 
   The turn signals and running (marker) lights  14  utilize LED&#39;s for their illumination. The turn signals and running lights  14  using LED&#39;s have more than 100,000 hours of life. The LED&#39;s of the turn signals and running lights  14  will last the lifetime of the vehicle, and therefore never need replacement. For a combat vehicle, this represents a dramatic improvement in logistics burden. The LED turn signals and running lights  14  also consume 75 percent less power and generate less heat than standard turn signals and marker lights, while providing an equivalent amount of light output. 
   The microprocessor controller provides precise control of the elevation position of the headlight  12 . The headlight  12  has at least three defined positions—a closed position, a low beam position, and a high beam position—and is adjustable to any emitting angle within its range of motion desired by the user. The controller uses onboard vehicle attitude information to provide automatic directional adjustment for the headlight  12 . The headlight  12  can also be manually controlled with a control device that feeds through the controller. The controller interfaces with the existing vehicle lighting wiring system and does not require any electrical modifications of the basic vehicle. The microprocessor controller is protected with transient voltage suppressors and voltage regulators to withstand harsh electrical noise, which is not uncommon in a combat vehicle application. 
   An electromechanical actuator  20  is used in conjunction with, and controlled by, the microprocessor controller to adjust the light emitting angle of the headlight  12  via the hidden interior hinge  22 . When the headlight  12  is at a desired position, the actuator  20  receives a brake command so that the actuator  20  is held in position, thereby eliminating movement of the headlight  12 . 
   The hidden interior hinge  22  is a key element of the light unit  10  of the lighting system of the present invention. The hidden hinge  22  interfaces between the electromechanical actuator  20  and the headlight  12  that is affixed to an armored door panel  241  that is part of the light unit housing  24 . The hidden interior hinge  22  is unique in that the center of rotation of the armored door panel  241  is outside of the housing  24  enclosure, while the hinge  22  itself is physically located inside the light unit housing  24 . This characteristic of the hinge  22  allows the door panel  241  to be opened without binding, even when thick armor and signature treatment materials are used for the door panel  241  and the light unit housing  24 . Further, the interior location of the hinge  22  provides a signature management factor as the hinge does not need to be mounted outside of the housing  24 . Ordinary externally mounted hinges extend beyond the profile of the vehicle hull, and therefore add to the signatures of the vehicle. The hinge  22  is made of rugged, heat-treated steel and is thus able to endure a combat vehicle environment of shock, vibration, and hard use. 
   The hinge  22  structure is shown in detail in  FIGS. 6-9 . The structure comprises a housing attachment plate  221  that is secured to the fixed portion of the light unit housing  24 , and a light fixture attachment plate  222  that is secured to the movable light fixture  16  of the unit  10 . An actuator arm socket  223  is pivotally attached to both the light fixture attachment plate  222  and the housing attachment plate  221 . The actuator arm socket  223  receives an arm from the electromechanical actuator  20  to drive the movement of the light fixture  16 . 
   The connection of the socket  223  to the housing attachment plate  221  and to the light fixture attachment plate  222  is accomplished by a “double jointed” mechanism that allows the hinge  22  to expand when driven by the actuator  20 . A first side of the arm socket  223  is pivotally attached to connecting lever  224 , which is in turn pivotally attached to the housing attachment plate  221  by means of connecting struts  2211  that are integral to the housing attachment plate  221 . A second side of the arm socket  223  is pivotally attached to a straight linkage bar  225 , which is in turn pivotally attached to the light fixture attachment plate  222  by means of integral connecting struts  2221  to form the second half of the double joint. 
   A pair of stabilizing hinge elements  229 , which are also “double jointed”, are situated on ether side of the actuator arm socket connection hinge element  230 . The stabilizing hinge elements comprise integral connecting struts  2212  on the housing attachment plate  221 , and similar connecting struts  2222  on the light fixture attachment plate  222 . The light fixture connecting struts  2222  each comprise a front connection boss  2223  and a rear connection boss  2224 . The front connection boss  2223  receives a rotating front connection axle  2225 , and the rear connection boss  2224  receives a rotating rear connection axle  2226 . Each front connection axle  2225  pivotally receives a first end of a pair of the straight linkage bars  225 . Each rear connection axle  2226  pivotally receives a first end of a pair of eccentric linkage bars  226 . 
   The second ends of the straight linkage bars  225  and the second ends of the eccentric linkage bars  226  are rotatably connected respectively with a first end of a three point hinge bar  227  and a midpoint of the hinge bar  227 . The second ends of both the straight linkage bars  225  and the eccentric linkage bars  226  are secured by connecting pins  228  that pass through receiving holes in the hinge bar  227 . The second ends of the three point hinge bars  227  are rotatably secured by connecting pins  228  that are secured in aligned holes in a lower side of the housing connecting struts  2211 . 
   The final pivot point of the interior hinge  22  is made by connecting another straight linkage bar  225  at a first end to a point between the two ends of the two sets of eccentric linkage bars  226 . The second ends of the straight linkage bars  225  that are connected to the bodies of the eccentric linkage bars  226  are rotatably secured by connecting pins  228  that are received in aligned holes in an upper side of the housing connecting struts  2211 . 
   The double jointed structure of the hinge  22  of the present invention gives the light unit  10  the unique capability of having the entire hinge  22  mechanism physically located below the upper surface of the housing  24 . However, when the actuator  20  drives the hinge  22 , the nominal axis of rotation of the hinge lies above the upper surface of the housing  24 . When the arm of the actuator  20  drives the actuator arm socket  223  forward, the hinge  22  expands and rotates the light fixture  16  outward. 
   The light unit housing  24  is constructed of armor materials and shaped as a trapezoid for signature management purposes. The trapezoid shape eliminates any right angle (90 degree) facets, which is beneficial in that right angle facets contribute to poor radar performance (high radar reflectance). The clean lines and smooth shape of the housing  24  also allows signature management coatings and materials to be readily bonded, applied, or attached to the outer surfaces of the housing  24  without any required redesign of the hinge  22  or of the mounting system for the light unit  10 . 
   While there are many satisfactory ways in which the light unit  10  can be mounted on the vehicle, in the preferred embodiment, the light unit housing  24  is secured to the vehicle hull  26  with an internal tab  28  that is mounted at the rear of the housing  24 . The tab  28  is received in a socket  30  affixed to the vehicle hull  26 . The front end of the housing  24  is secured by two hex bolt fasteners  32  received in mounting ears  34  at a front inside edge of the housing  24 . The light unit  10  is installed by first connecting the electrical feeds  36 , then placing the light unit  10  assembly over the socket  30  mounted on the vehicle hull  26  and sliding the light unit  10  toward the front of the vehicle so that the tab  28  engages the socket  30 . Then, with the LED for the turn signals and running lights  14  removed, the two front hex bolts  32  are inserted. The LED is then re-installed with multiple screws located around the bezel, and the system is ready for use. 
   The above disclosure is not intended as limiting. Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the restrictions of the appended claims.

Technology Classification (CPC): 8