车灯研发设计过程PPT课件

UpdatedateI1,ProductDesignCommunication,Vehicle:VolvoXC90Lamp:V526RL,Summary,ProjectintroductionStyleandlayoutExplosiveviewOpticalSolutionThermalandcondensationVibrationsimulationMechanicalsimulationIsostatismProcessManufacturabilityElectronics,Projectintroduction,Designevolution:Expertise2011.11RFQ:2011.11-2012.7PH1:2012.8-2013.2PH2:2013.3-2013.8,Styleandlayout,Tail(21Leds)Fresnelandmicro-prism,Side-marker(22Leds)Fresnelandmicro-prism,Side-reflex,Stop(15Leds)Fresnelandcubeinnerlens,Reverse(PSX24Bulb),TI(12Leds)Fresnelandcubeinnerlens,Fog(3Leds)Fresnelandcubeinnerlens,718mm,Explosiveviewandsections,OpticalSolution,OpticalSolution,Fresnel+MicroprismsolutionForconstantopticalaspectofTailandSide-marker.,OpticalSolution,Fresnel+IcescreenForStop-TI-Fogfunction.,Fresnelscreen,Icescreen,50cmforSAEregulation(Stop),50cmforSAEregulation(TI),100cmbetweenFogandStop,Fog,OpticalSolution,P24WBulb,PSX24WforReverseFunction(mountinginYdirection),15mmheight,Thermalandcondensation,ThistestistosimulatetheimpactofthePSX24Wbulbtoallothercomponents.,Thermalandcondensation,PC,temperaturelimit150C:NOK,SolutionistomakeShinymetallizationonrearsurfaceofmainbezel,Thermalandcondensation,PMMA,temperaturelimit105-110C:NOK,SolutionistoChangematerialofstopscreentoPMMA-HToradjustFluxofPSX24Wbulb.,Thermalandcondensation,Smallriskyarea,itsok.,PMMA,temperaturelimit105-110C:NOK,Thermalandcondensation,PC,temperaturelimit150C:NOK,Smallriskyarea,itsok.,Thermalandcondensation,Tail/SMPCB,AddSMPCB,StopLEDsPCB,TILEDsPCB,Driverboard,Thermalandcondensation,Simulation20:60,SAE,TAIL,SM,STOP,TI,Pmax,Thermalandcondensation,Givenareaiscoldareaandtheairvelocityisverylowhere.Wemakeagore-texpadtosolvethisproblem,Thermalandcondensation,Simulationteamsproposetoincreasethegapat5mmMin.asthestylelimit,wekeepcurrentdefinition.,VibrationMECHANICALSIMULATION,FenderModalHarmonicPSD,TrunkModalHarmonicPSDSlamming,Vibrationsimulation,Vibrationsimulation,Vibrationsimulation,6-screwstoincreasetheconnectionbetweenMainmaskandhousing,Lotsoflocationdottodecreasethe“L”,Addre-enforceribonhousingtoincrease“A”,Vibrationsimulation,Mode172Hz,Mode279Hz,Vibrationsimulation,Stressfatiguelimitof21MPa,blackbezel,mainbezel,Maxstressatcontactsurface,Vibrationsimulation,Penetration:7.5-3.5-0.7=3.3mmlensandmainbezel,Gap=0.7mm,ContactriskinYdirection,visible,Gap=3.5mm,Penetration:7.5-0.7-1.4=5.4mmsidemarkerandmainbezel,mechanicalsimulation,Simulationtarget:1.EnsureRLresisttotheclampingeffort2.EnsureRLdisplacement.Applythetorqueof6N.MontheRLscrewfixing1)Applyadisplacementof+/-1.5mmonRLtrunkbottomscrewfixing2)ChecktheVon-Misesstress(mechanicalresistance),mechanicalsimulation,AddribsonHousing,Increaselocalareathicknessfrom2.5mmto3mmlocal,AddribsonHousing,Itsokaftermodification,Itsokaftermodification,mechanicalsimulation,Displacementresult,Isostatism,A1,A2,AdjustedscrewsA3,B1,B2C1,Half-B,C,C,B,BC,B,A,auxiliary-AB,Isostatism,Isostatism,Half-B,C,B,A,Half-B,C,A,A,Isostatism,BC,C,A,A,A,A,B,C,C,A,A,A,A,A,A,C,B,B,Plsfindtheinnercomponentsfixationasbelow:,Process,Step-1HousingAssem(WithHarness,gasket,screws,P24WbulbsCP),Step-2WithStopandTIFresnelAssem+Reversereflector(PCBsandFresnelscreens,reversereflector),Step-3WithBackbezelAssem(Backbezel,Tailblade,Sidemarker,PCBsandharness),Step-4WithMainbezelAssem(Mainmask,StopandTIscreen,Reflexreflector),Step-5WithLens(Hot-plateweldingprocess),Manufacturability,Lens,Housings,Mainbezel,Asimagesshownabove,therearebigdeflectiononLens,HousingandMainbezel.wecanonlyimproveitbymoldadjustment(cooling,adjustingJigs,moldadjustment.),Manufacturability,WetakemuchtimeadjustingthicknessofMainbezel.Baseonitsstructuredefect,thecomponentstillhavemuchriskonWeldinglines,airtrapsandsinkmark.,Manufacturability,Ejector,Originalstate,ejectorstate,Takethelensbymanipulator,Extractdirection,Manufacturability,ThreeslidersforReversereflector.,SliderforBulbmountinginYdirection,Slider-Topistoavoidopticalsurfacelosing,Slider-Bottomistoavoidopticalsurfa