车灯研发设计过程（PPT38页)

UpdatedateI1ProductDesignCommunicationVehicle:VolvoXC90Lamp:V526RLSummary1.Projectintroduction2.Styleandlayout3.Explosiveview4.OpticalSolution5.Thermalandcondensation6.Vibrationsimulation7.Mechanicalsimulation8.Isostatism9.Process10.Manufacturability11.ElectronicsProjectintroductionDesignevolution:Expertise2011.11RFQ:2011.11-----2012.7PH1:2012.8-------2013.2PH2:2013.3-------2013.8SidereflexStyleandlayoutTail(21Leds)Fresnelandmicro-prismSide-marker(22Leds)Fresnelandmicro-prismSide-reflexStop(15Leds)FresnelandcubeinnerlensReverse(PSX24Bulb)TI(12Leds)FresnelandcubeinnerlensFog(3Leds)Fresnelandcubeinnerlens718mmExplosiveviewandsectionsOpticalSolutionOpticalSolutionFresnel+MicroprismsolutionForconstantopticalaspectofTailandSide-marker.OpticalSolutionFresnel+IcescreenForStop-TI-Fogfunction.FresnelscreenIcescreen50cm²forSAEregulation(Stop)50cm²forSAEregulation(TI)100cmbetweenFogandStopFogOpticalSolutionP24WBulbPSX24WforReverseFunction(mountinginYdirection)15mmheightThermalandcondensationBulborLEDLEDRthFunctionDissipatedPowerat13.5V(W)SimulationTestat60°CPSX24W*Reverse18.2W5minon/5minoff24WContinuouslyonThistestistosimulatetheimpactofthePSX24Wbulbtoallothercomponents.ThermalandcondensationPC,temperaturelimit150°C:NOKSolutionistomakeShinymetallizationonrearsurfaceofmainbezelThermalandcondensationPMMA,temperaturelimit105-110°C:NOKSolutionistoChangematerialofstopscreentoPMMA-HToradjustFluxofPSX24Wbulb.ThermalandcondensationSmallriskyarea,it’sok.PMMA,temperaturelimit105-110°C:NOKThermalandcondensationPC,temperaturelimit150°C:NOKSmallriskyarea,it’sok.ThermalandcondensationTail/SMPCBAddSMPCBStopLEDsPCBTILEDsPCBDriverboardThermalandcondensationSimulation20:60℃,SAE,TAIL,SM,STOP,TI,PmaxThermalandcondensationGivenareaiscoldareaandtheairvelocityisverylowhere.Wemakeagore-texpadtosolvethisproblemThermalandcondensationSimulationteamsproposetoincreasethegapat5mmMin.asthestylelimit,wekeepcurrentdefinition.VibrationMECHANICALSIMULATIONFenderModalHarmonicPSDTrunkModalHarmonicPSDSlammingVibrationsimulationVibrationsimulationVibrationsimulation6-screwstoincreasetheconnectionbetweenMainmaskandhousingLotsoflocationdottodecreasethe“L”Addre-enforceribonhousingtoincrease“A”VibrationsimulationMechanicalSimulationObjective:Context:CheckfrequencyonthelampassemblyCheckfirstfrequencyTools:Referencedoc:Criteria:ANSYS13SP2VibrationmethodologyV3VibrationMaterialV9Firstfrequency100HzSecondfrequency120HzResultsandconclusion:Thefirstfrequencyis72Hz.Contactriskbetweenmainbezelandlens,mainbezelandsidemarkerKORecommendations:1.AddcontactsbetweenblackbezelandhousingMode172HzMode279HzUpdatedateI23VibrationsimulationStressfatiguelimitof21MPablackbezelmainbezelMaxstressatcontactsurfaceVibrationsimulationPenetration:7.5-3.5-0.7=3.3mmlensandmainbezelGap=0.7mmContactriskinYdirection,visibleGap=3.5mmPenetration:7.5-0.7-1.4=5.4mmsidemarkerandmainbezelmechanicalsimulation•Simulationtarget:1.EnsureRLresisttotheclampingeffort2.EnsureRLdisplacement.Applythetorqueof6N.MontheRLscrewfixing1)Applyadisplacementof+/-1.5mmonRLtrunkbottomscrewfixing2)ChecktheVon-Misesstress(mechanicalresistance)mechanicalsimulationAddribsonHousingIncreaselocalareathicknessfrom2.5mmto3mmlocalAddribsonHousingIt’sokaftermodificationIt’sokaftermodificationmechanicalsimulationDisplacementresultIsostatismA1A2AdjustedscrewsA3B1B2C1Half-BCCBBCBAauxiliary-ABIsostatismIsostatismHalf-B,CBAHalf-B,CAAIsostatismBCCAAAABCCAAAAAACBBPlsfindtheinnercomponentsfixationasbelow: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)ManufacturabilityLensHousingsMainbezelAsimagesshownabove,therearebigdeflectiononLens,HousingandMainbezel.wecanonlyimproveitbymoldadjustment(cooling,adjustingJigs,moldadjustment…..)ManufacturabilityWetakemuchtimeadjustingthicknessofMainbezel.Baseonitsstructuredefect,thecomponentstillhavemuchriskonWeldinglines,airtrapsandsinkmark.ManufacturabilityEjectorOriginalstateejectorstateTakethelensbymanipulatorExtractdirectionManufacturabilityThreeslidersforReversereflector.SliderforBulbmountinginYdirectionSlider-TopistoavoidopticalsurfacelosingSlider-BottomistoavoidopticalsurfacelosingManufacturabilityGeneralthickness5mmFormassivelightaspectofSidemarker.Slidertomoldsideopticalandlocationarea.Micro-opticalfeasibilityneedtobeconfirmedwithDBM.ElectronicsVerysmallsizeforthisPCB