车灯研发设计过程

车灯研发设计过程2024/3/12车灯研发设计过程Summary

ProjectintroductionStyleandlayoutExplosiveviewOpticalSolutionThermalandcondensationVibrationsimulationMechanicalsimulationIsostatismProcessManufacturabilityElectronics车灯研发设计过程ProjectintroductionDesignevolution:Expertise2011.11RFQ:2011.11-----2012.7PH1:2012.8-------2013.2PH2:2013.3-------2013.8Sidereflex车灯研发设计过程StyleandlayoutTail(21Leds)Fresnelandmicro-prismSide-marker(22Leds)Fresnelandmicro-prismSide-reflexStop(15Leds)FresnelandcubeinnerlensReverse(PSX24Bulb)TI(12Leds)FresnelandcubeinnerlensFog(3Leds)Fresnelandcubeinnerlens718mm车灯研发设计过程Explosiveviewandsections车灯研发设计过程OpticalSolution车灯研发设计过程OpticalSolutionFresnel+MicroprismsolutionForconstantopticalaspectofTailandSide-marker.车灯研发设计过程OpticalSolutionFresnel+IcescreenForStop-TI-Fogfunction.FresnelscreenIcescreen50cm²forSAEregulation(Stop)50cm²forSAEregulation(TI)100cmbetweenFogandStopFog车灯研发设计过程OpticalSolutionP24WBulbPSX24WforReverseFunction(mountinginYdirection)15mmheight车灯研发设计过程ThermalandcondensationBulborLEDLEDRthFunctionDissipatedPowerat13.5V(W)SimulationTestat60°CPSX24W*Reverse18.2W5minon/5minoff24WContinuouslyonThistestistosimulatetheimpactofthePSX24Wbulbtoallothercomponents.车灯研发设计过程ThermalandcondensationPC,temperaturelimit150°C:NOKSolutionistomakeShinymetallizationonrearsurfaceofmainbezel车灯研发设计过程ThermalandcondensationPMMA,temperaturelimit105-110°C:NOKSolutionistoChangematerialofstopscreentoPMMA-HToradjustFluxofPSX24Wbulb.车灯研发设计过程ThermalandcondensationSmallriskyarea,it’sok.PMMA,temperaturelimit105-110°C:NOK车灯研发设计过程ThermalandcondensationPC,temperaturelimit150°C:NOKSmallriskyarea,it’sok.车灯研发设计过程ThermalandcondensationTail/SMPCBAddSMPCBStopLEDsPCBTILEDsPCBDriverboard车灯研发设计过程ThermalandcondensationSimulation20:60℃,SAE,TAIL,SM,STOP,TI,Pmax车灯研发设计过程ThermalandcondensationGivenareaiscoldareaandtheairvelocityisverylowhere.Wemakeagore-texpadtosolvethisproblem车灯研发设计过程ThermalandcondensationSimulationteamsproposetoincreasethegapat5mmMin.asthestylelimit,wekeepcurrentdefinition.车灯研发设计过程VibrationMECHANICALSIMULATIONFenderModalHarmonicPSD

TrunkModalHarmonicPSD

SlammingVibrationsimulation车灯研发设计过程Vibrationsimulation车灯研发设计过程Vibrationsimulation6-screwstoincreasetheconnectionbetweenMainmaskandhousingLotsoflocationdottodecreasethe“L”Addre-enforceribonhousingtoincrease“A”车灯研发设计过程VibrationsimulationMechanicalSimulationObjective:Context:CheckfrequencyonthelampassemblyCheckfirstfrequencyTools:Referencedoc:Criteria:ANSYS13SP2VibrationmethodologyV3VibrationMaterialV9Firstfrequency>100HzSecondfrequency>120HzResultsandconclusion:Thefirstfrequencyis72Hz.

Contactriskbetweenmainbezelandlens,mainbezelandsidemarkerKORecommendations:AddcontactsbetweenblackbezelandhousingMode172HzMode279Hz车灯研发设计过程VibrationsimulationStress<fatiguelimitof21MPablackbezelmainbezelMaxstressatcontactsurfaceUpdatedateI23车灯研发设计过程VibrationsimulationPenetration:7.5-3.5-0.7=3.3mmlensandmainbezelGap=0.7mmContactriskinYdirection,visibleGap=3.5mmPenetration:7.5-0.7-1.4=5.4mmsidemarkerandmainbezel车灯研发设计过程mechanicalsimulationSimulationtarget:1.EnsureRLresisttotheclampingeffort2.EnsureRLdisplacement.

Applythetorqueof6N.MontheRLscrewfixing1)Applyadisplacementof+/-1.5mmonRLtrunkbottomscrewfixing

2)ChecktheVon-Misesstress(mechanicalresistance)车灯研发设计过程mechanicalsimulationAddribsonHousingIncreaselocalareathicknessfrom2.5mmto3mmlocalAddribsonHousingIt’sokaftermodificationIt’sokaftermodification车灯研发设计过程mechanicalsimulationDisplacementresult车灯研发设计过程IsostatismA1A2AdjustedscrewsA3B1B2C1车灯研发设计过程Half-BCCBBCBAauxiliary-ABIsostatism车灯研发设计过程IsostatismHalf-B,CBAHalf-B,CAA车灯研发设计过程IsostatismBCCAAAABCCAAAAAACBB车灯研发设计过程Plsfindtheinnercomponentsfixationasbelow:ProcessStep-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)车灯研发设计过程ManufacturabilityLensHousingsMainbezelAsimagesshownabove,therearebigdeflectiononLens,HousingandMainbezel.wecanonlyimproveitbymoldadjustment(cooling,adjustingJigs,moldadjustment…..)车灯研发设计过程ManufacturabilityWetakemuchtimeadjustingthicknessofMainbezel.Baseonitsstructuredefect,thecomponentstillhavemuchriskonWeldinglines,airtrapsandsinkmark.车灯研发设计过程ManufacturabilityEjectorOriginalstateejectorstateTakethelensbymanipulatorExtractdirection车灯研发设计过程ManufacturabilityThreeslidersforReversereflector.SliderforBulbmountinginYdirectionSlider-TopistoavoidopticalsurfacelosingSlider-Bo