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Provide auto manufacturers with prototypes of headlights

by:Vowin Rapid Prototyping     2023-02-04
Why are headlights so important? In everyday communication, we often conceptualize headlights and headlights. But more precisely, headlight is a term referring to the device itself, while headlight is the light beam generated and distributed by the device. Why are headlights so important? Whether it is day or night, we will see countless vehicles on the road. According to the National Transportation Agency, although only 25 percent of traffic will be driven in the dark, accidents are far more likely to occur than that percentage. Therefore, headlights are very important, providing us with travel safety and allowing headlight designers to track a driver's eyes to better understand their behavior. The performance of headlights is being continuously optimized not only in the automotive sector, but also from small generators for bicycles to trains and airplanes, requiring work for mechanical integration. A good front lighting system requires the cooperation of various components in order to provide end customers with a better visual experience and perceived quality. The prototype headlight is mainly composed of a lens, a glass frame, a light guide plate, a reflector, and a housing. The headlight baffle is provided with a baffle on the front upper side of the filament in the vacuum wick. Its function is to block direct light when the filament is lit. If the upward light of this part of the car headlights is not blocked, not only will it cause severe glare to the driver of the oncoming vehicle, but the scattered light will also form a light curtain in front of the car in the rain. or foggy conditions, reducing the driver's vision of the car. Prototype baffles are usually made of PMMA or ABS, and their performance requirements are heat resistance, metallization, and high surface quality. The light source of the headlight reflector headlight system comes from the bulb, but it also needs the cooperation of the reflector. The reflector is an internal component of the headlight and belongs to the auxiliary optical element. The function is to perform secondary light distribution on the light, so that the light of the LED headlights of the car can be gathered. It can be said that they are the core of the light effect of lighting equipment. Without such a core application, the lighting market will return to its primitive stage. The reflector effectively amplifies the light output of the bulb through the principle of concentrating light with a concave mirror. In addition, it has an anti-glare function to make the driver more focused. There are three production technologies for reflectors: 1. Plastic reflectors: one-time release, poor optical performance, low cost, and the disadvantage is poor temperature resistance, often used in lamps that require low temperature. 2. Metal reflectors: stamping and polishing processes are required. The advantages are moderate cost and high temperature resistance. They are often used in flashlights and portable lamps. 3. Glass reflector: one-time stripped film, high optical precision, invisible memory, high temperature resistance, the disadvantage is high cost, fragile and bulky. Often used in high-quality products that do not require movement. Such as movie projectors, searchlights, locomotive headlights, etc. Combining the advantages and disadvantages of the above three options, we usually use ABS prototype reflectors or chrome aluminum prototype reflectors. Prototype chrome aluminum reflector. Aluminum material has good ductility, is easy to process, and has a high heat distortion temperature, which is suitable for electroplating and coating treatment. After vacuum aluminum plating, a thin and stable oxide layer will be formed on the surface, which is highly corrosion-resistant. The closed vacuum suction mirror is mainly a paraboloid formed by parabola rotation. During the production of the mirrors, a vacuum coating process is used to evaporate the aluminum on the inner surfaces. It has very high brightness, and the brightness of reflected light is more than 6000 times higher than that of the filament itself. Some headlamps only rely on the special structure of the reflector, complex shape and high processing accuracy to meet the light distribution requirements, but the design, calculation, mold precision and processing technology of this reflector are still very difficult. The image below shows a prototype of the reflector produced by the team. The internal shape of the mirror consists of various paraboloids. The accuracy of each profile has a strong effect on the type of light source. This is the biggest processing problem, but the Wooneng team has very good experience in handling such workpieces, not only the entire surface is glossy, but also achieves a class A surface effect and greatly improves the reflectivity. Headlight Housing The main function of the headlight housing is to support the headlight assembly and hold the vehicle headlight in place to maintain the correct position on the vehicle's dashboard. Different car makes and models have different front-end assembly settings, so the location of the headlight housing installed will also depend on your driving configuration. Some headlight systems are relatively simple in structure, and the housing is designed with some bolts that can be easily fixed near the grille. Some vehicles are more complicated, requiring the bumper to be removed and secured with a dozen bolts. Headlight housings are made of plastic or metal. But in the automotive industry, people will prefer plastic because the overall evaluation of plastic is mechanical, crack resistant, strong, chemically resistant to acid and alkali corrosion, and light weight. There are also many types of plastic materials, and you can choose the right material based on the temperature and impact properties of your application. In the headlight prototype manufacturing, the housing is made of ABS or PC/ABS, and its performance requirements are dimensional stability and heat resistance. Conclusion The headlight system is the most recognizable and unique element of a car's exterior. In addition to the common plastic ABS, PC, and metal aluminum parts, many new materials are constantly being used in the current market. The integration and design of all components of the headlight system need to be unified to meet the safety of use so that the driver can experience comfort and meet regulatory standards. Vowinwill bring you more automotive hand model solutions, and work with you to increase productivity and reduce engineering development. We can evaluate material properties for the first time to bring your CAD realization from early concept to prototype to series production.
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