Optical design for a cost-effective low-beam headlamp with a white light LED
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Optical design for a cost‑effective low‑beam headlamp with a white light LED Wen‑Shing Sun1 · Chuen‑Lin Tien2 · Jian‑An Chen1 · Jhe‑Syuan Lin1 Received: 11 May 2020 / Accepted: 13 October 2020 © Springer Science+Business Media, LLC, part of Springer Nature 2020
Abstract We present a design for a cost-effective low-beam automotive headlamp with a single light-emitting diode (LED) light source. The proposed design consists of a white LED, an elliptical reflector, a parabolic reflector, a toric lens, a filter, and a prism array. The white LED had a luminous flux of 146 lm. Non-sequential rays were used to improve the efficiency and a toric lens was employed to optimize the light pattern on a 25 m screen which appeared as rectangular with a high degree of uniformity. In addition, the filter and the prism array were modified to correct the measured light pattern results to meet the requirements of ECE R112. We set the reflectivity of the elliptical and parabolic reflectors for the compound reflectors to be 95%. The transmittance of each surface of the toric lens is 98%. The total received lumens was 80.62 lm, and the overall efficiency was 55.22%. Keywords Optical design · Low-beam headlamp · Light-emitting diode (LED) · Toric len · Prism array
1 Introduction The designs of light sources for automotive headlamps are being continually updated as the technology changes. The main focus in headlamp design is the best use of the optical characteristics of the rays, taking advantage of refraction, reflection, and total reflection, to control the ray tracing results and to achieve the light distribution specified in the regulations. Many optical design methods for automotive headlamps have been developed. Lindae developed an automotive headlamp design based on a poly-ellipsoid-system (PES) (Lindae 1985). Jenkins et al. (1996) utilized distributive lighting to achieve a low-beam headlamp design. Their challenge was to design an efficient lamp package that ensured angular distribution of the flux which would meet legal and customer requirements. Zerhau-Dreihoefer et al. (2002) developed some light source modeling methods for automotive lighting devices, using different light source modeling techniques for the process of carrying out the calculations and simulating automotive lighting devices. Cassarly et al. (2002) measured the spatial luminance * Chuen‑Lin Tien [email protected] 1
Department of Optics and Photonics, National Central University, Chungli 32001, Taiwan, ROC
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Department of Electrical Engineering, Feng Chia University, Taichung 40724, Taiwan, ROC
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distributions over a range of view angles, which is an important consideration for lamps with elliptical reflectors and LEDs. In 2006, Cvetkovic et al. (2006) employed the 3D simultaneous multiple surface (SMS) method to design an LED headlamp with good uniformity and high intensity using one refractive and reflective freeform surface. Chen et al. (2010a) designed a vehicle headlamp based on a fibe
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