EP0125353A1 - Kraftfahrzeugscheinwerfer mit Optik enthaltendem Reflektor - Google Patents

Kraftfahrzeugscheinwerfer mit Optik enthaltendem Reflektor Download PDF

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Publication number
EP0125353A1
EP0125353A1 EP83302633A EP83302633A EP0125353A1 EP 0125353 A1 EP0125353 A1 EP 0125353A1 EP 83302633 A EP83302633 A EP 83302633A EP 83302633 A EP83302633 A EP 83302633A EP 0125353 A1 EP0125353 A1 EP 0125353A1
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EP
European Patent Office
Prior art keywords
light
reflector
recited
ellipsoids
pattern
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Application number
EP83302633A
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English (en)
French (fr)
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EP0125353B1 (de
Inventor
Edward Allan Snyder
Michael Phillip Teter
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Corning Glass Works
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Corning Glass Works
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Publication date
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Priority to DE8383302633T priority Critical patent/DE3380703D1/de
Priority to EP83302633A priority patent/EP0125353B1/de
Publication of EP0125353A1 publication Critical patent/EP0125353A1/de
Application granted granted Critical
Publication of EP0125353B1 publication Critical patent/EP0125353B1/de
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • F21S41/32—Optical layout thereof
    • F21S41/33—Multi-surface reflectors, e.g. reflectors with facets or reflectors with portions of different curvature
    • F21S41/334—Multi-surface reflectors, e.g. reflectors with facets or reflectors with portions of different curvature the reflector consisting of patch like sectors
    • F21S41/335—Multi-surface reflectors, e.g. reflectors with facets or reflectors with portions of different curvature the reflector consisting of patch like sectors with continuity at the junction between adjacent areas

Definitions

  • This invention relates to automotive headlights, and more particularly, to a headlight in which the reflector is contoured to meet the required light specifications and the lens is replaced with a clear cover plate which can be placed at any angle which is aerodynamically desirable.
  • Sealed beam automotive headlights include a paraboloidal reflector which collects light from an incandescent filament bulb and directs it towards a lens.
  • the lens has flutes which shift and spread the light into a beam pattern which meets the specifications set by the Society of Automotive Engineers. Because the standard lens is the optically active element having fluting with flute risers and edges, its positioning with respect to the bulb and reflector is critical. Desirably the position of the lens should be nearly normal to the light emanating from the bulb and reflector, since riser glare becomes worse when the lens is slanted at an angle thereto. That is, the lens fluting produces uncontrolled light, known as glare, from the flute risers and edges.
  • U.S. Patents 153,341-Jacobsen and 1,346,268-Goodley show early attempts to produce lamps with the optics in the reflectors.
  • U.S. Patents 3,511,983-Dorman and 4,149,277-Dorman show more recent attempts to provide a lamp in which the reflector produces a desired light pattern. These reflectors are not suitable for meeting the more stringent automotive specifications.
  • a reflector having at least one reflective surface which directs light from a light source in a desired pattern, said surface being smooth and continuous.
  • a sealed beam headlight has reflector surfaces which direct light from the bulb through a clear, unfluted front cover in a pattern which meets the specification for automotive headlights.
  • the reflective surface is smooth and continuous which makes the reflector easy to fabricate and eliminates undesirable reflector flute glare. Since there are no flutes, the cover may be aerodynamically swept, yielding both styling and performance advantages upon which manu- factuers now place a premium.
  • the headlight is produced by a process comprising the steps of:
  • the digitally modeled reflective surface is modified in an interative procedure to produce a light intensity pattern which best meets automotive specifications and wherein the reflective surface is smooth and continuous.
  • a digitally modeled light source which closely approximates the light intensity from a tungsten halogen lamp is used.
  • a plurality of parabolic reflectors made up the headlight. The prior art design processes merely determined where the light from each parabolic facet was directed and accordingly changed this direction to obtain the desired light pattern.
  • the present invention traces a very large number of ray paths, e.g. 500,000, from an accurately modeled distributed light source to the reflective surface. The ray paths are projected, from the normal to the reflective surface, onto a surface such as a sphere surrounding the reflector.
  • Light intensity across a portion of the spherical surface is determined by counting the number of light rays intersecting each unit area. The intensity thus determined can be digitally compared to the S.A.E. specifications and a performance function, indicating the match with the specification, is generated.
  • This shape of the digitally modeled reflective surface is changed in an interative procedure to optimize the performance function. At each change in the shape, the junctions between the surfaces are blended, or smoothed, so that there are no sharpe edges, or discontinuities which makes fabrication difficult.
  • the automotive headlight of this invention includes a bulb 11 having a filament to provide a light source and a clear front cover 12 which may be swept at an aerodynamically desired angle with respect to the headlight.
  • a reflector 13 encloses the bulb and is sealingly attached to the front cover 12.
  • the reflector has a reflective surface which directs light from the bulb 11 through the front cover in a pattern which meets the specifications for automotive headlights.
  • the reflector has reflective surfaces which include a center modified ellipsoid 14 and two edge modified ellipsoids 15 and 16.
  • Edge ellipsoid 15 joins center ellipsoid 14 in a smooth, continuous junction 17; similarly, edge ellipsoid 16 joins center ellipsoid 14 in a smooth continuous junction 18.
  • the center surface 14 is an ellipsoid with a smooth vertical bump 21 added to the center.
  • Ellipsoidal surface 14 is concave and is tilted off the axis of the headlight.
  • Ellipsoids 14, 15 and 16 are concave and are modified from true parabolic surfaces in a manner which produces a prescribed light pattern, and which produces smooth, continuous junctions between the surfaces.
  • a center platform 22 which may have sharp edges provides for attachment and alignment of the lamp, but it is not part of the reflecting surface. In accordance with the present invention, such sharp edges are avoided over substantially all of the reflective surface.
  • Fig. 3 depicts the computer aided process by which this type of reflector was produced.
  • Fig. 4 depicts a prior art reflector in a manner which shows the advantages of the present invention.
  • Fig. 4 depicts a prior art attempt, known to the inventors, of reducing the depth of the reflector by using a plurality of parabolic surfaces instead of a single parabolic surface. Note that the inersections 23 and 24 between the parabolic surfaces present sharp edges which are not modeled and are difficult to fabricate. Furthermore, the portions of the reflector between 23 and 25 and between 24 and 26 are shadowed. They do not contribute to light reflection. The reflector of Fig. 4 does not have a normal vector at the junctions 23 and 24.
  • the minimum radius of curvature is very small at 23 and 24.
  • the surface slope is discontinuous, that is the minimum radius of curvature is arbitrarily small.
  • smooth and continuous junctions means that the conditions depicted at 23 and 24 in Fig. 4 are not present, that the normal is always well defined.
  • the shape involves separate reflector surfaces, junctions between surfaces are treated as any other reflecting -area. Resulting intensity calculations include effects of the smooth junctions, so that the junctions are made large enough to facilitate the glass forming process.
  • the minimum radius of curvature is less than about 0.002 mm there are increasing problems in forming glass to a sharp edge.
  • the preferred embodiment of this invention has a minimum radius of curvature of 0.0076 mm, but the invention can be practiced with surfaces having smooth junctions with a minimum radius of curvature greater than about 0.002mm.
  • the prior art does not deal with junctions, the junctions in an actual product must be kept as sharp as possible, i.e., the radius of curvature must be arbitrarily small.
  • the reflector of the present invention has no such problem, since the shape is chosen to have a large minimum radius of curvature at the junctions.
  • the computer aided process of'this invention includes digitizing the prescribed light pattern as an input to the digital computer, the step being indicated at 27.
  • the SAE specifications are those set forth in Table I - Test Point Values for 7 in. (178 millimeter) Type 2 Seal Beam Unites, listed in S.A.E. J . 5 79C, page 23.31 of Report of Lighting Division Approved, January 1940, and last revised by Lighting Committee, December 1974.
  • the parameters of a plurality of shape functions specifying the surface of a reflector are digitized and provided as an input to the digital computer.
  • the shape functions are a center modified ellipsoid and two edge modified ellipsoids.
  • the coefficients of these ellipsoids are the parameters which are modified to meet the light pattern specifications and to produce smooth, continuous junctions between the edges of the ellipsoids.
  • the optimization of these coefficients is indicated at 29. This includes choosing a particular set of coefficients for the shape functions as indicated at 30, and using this reflector shape with a plurality of light paths to find the resulting light intensity distribution.
  • the list of light rays are produced from a digital computer model of a tungsten halogen lamp, indicated at 31.
  • this model includes a transverse filament 32 with a temperature distribution along its length. That is, as is normal, filaments are cool at their ends and hotter in the middle. The resulting light rays are refracted through an envelope which is modeled as a quartz cylinder 33 with opaque end caps.
  • the light intensity from this digital model lamp is generated by a list of ray paths leaving the envelope surface.
  • a ray from the envelope is tested to determine whether it intersects the reflector. If it does not, it is projected directly onto a sphere surrounding the reflector. If a ray path does intersect, as at the point 35 in Fig. 6, it is projected onto the surface of the sphere surrounding the reflector. For example, the ray path which is reflected at 35, intersects the sphere at the point 36.
  • Actual intensities are determined only for a 30° by 8° screen on the sphere the screen being indicated at 37 in Fi g . 6. Intensities are determined by counting the number of rays per unit area to hit the sphere.
  • the step 38 depicts the model of the reflection and the generation of the list of rays on the sphere around the reflector.
  • the theoretical surfacenormal at the point of intersection with the reflector e. g. the point 35 in Fig. 6
  • the description of the reflector, from the digital computer steps 28, 2-9 and 30, is used to find the normal at the point of intersection.
  • Any real reflector is distorted from the theoretical shape by forming inaccuracies. This distortion is modeled in accordance with the present invention by allowing the surface normal to vary about the theoretical normal.
  • A.value of 20 1° was chosen for use in this model by matching actual measurements to model predictions on a previous design.
  • the reflected ray is finally calculated using this distorted normal and the incident ray.
  • the light intensity across a surface of the sphere is determined as indicated at 39. This is done by counting the number of rays paths intersecting each unit area on the sphere screen. These values are compared to the prescribed light pattern as indicated at 40. For each shape which is tried, a performance factor, referred to as PFUN, is determined. The performance factor is a measure of how the light intensity pattern for the shape being tested matches the S.A.E. specifications.
  • Steps 30,38,39and 40 are repeated for different shapes, that is for different surface coefficients.
  • the shape which produces a light intensity best matching the prescribed light pattern is determined. This is done by choosing the set of coefficients having the optimum performance function, in this case the minimum value of PFUN. This results in the selection of the best set of coefficients as indicated at 42.
  • the candela values at each of a plurality of points are printed out as indicated at 43.
  • Appendix II lists a typical printout. The printout lists candela values at 60 feet for each of 26 test points corresponding with the S.A.E. test points. Note that of the 26 test points, only test point 25 has a value, 7.71, that is out of spec. In the present case a reflector surface has been produced which substantially meets S.A.E. specifications.
  • the designer may determine that a better light intensity distribution pattern must be produced.
  • the computer program to be subsequently described has a capability of repeating the process for different shape functions which the designer may choose. The designer also may choose which coefficients are varied in the process.
  • the best shape is selected as indicated at 44 in Fig. 3. This shape is used in the fabrication of reflectors.
  • Fig. 7 shows a computer generated candela diagram of a light intensity pattern for a reflector designed by this process.
  • Fig. 7 is the low beam pattern and
  • Fig. 8 is the high beam pattern.
  • the dashed lines are contours of 2000 candela and the solid lines are contour lines of 10,000 candela. That is, in Fig. 7, the contour line 45 represents 2,000 candela, the contour line 46 represents 24,000 candela and the contour lines in between are intervening candela values.
  • the beam pattern is shifted down and to the right as is required in automotive specifications.
  • Fig. 8 a wide high intensity beam is produced, shifted only slightly down into the right as is required by automotive specifications.
  • Appendix I lists, by way of example, a computer program which is suitable for performance on a Univac 1100/81 computer. This listing is provided only for aid in practicing the invention by programming and debugging a system which is suitable for the particular application. As with all computer programs it should not be assumed that the program will run without the usual debugging.
  • the program includes a number of subroutines which carry out the steps of Fig. 3 in the following manner.
  • ENV step 34, models a tungsten halogen lamp. It writes the position and direction of a ray onto file 14. It models radiation from a cylinder with axial temperature distribution, then determines filament blocking, end cap blocking, and ewelope refraction.
  • RUN step 29, is the main program for optimization It calls OPT2.
  • NITER is the number of iterations which are run.
  • OPT2 steps 30 and 41, is a multivariate optimizer. It looks for the least value of the performance function PFUN with variation in the vector XNEXT. The optimizer compares performance indices for several sets of 8 coefficients and guesses at a better set. Repeating this process many times finds a local minimum of the performance index, giving the best set of coefficients for the given shape function. This subroutine attemps to minimize the performance function. OPT2 calls subroutine PFUN.
  • PFUN runs reflection and performance subroutines. It returns performance for some set of variables (DX in this case). To find shape, it would use S vector, not DX.
  • RAYR step 38, models the reflection. It takes rays from file 14, finds intersections of the rays with the reflector, finds normal at intersection, distorts normal, finds reflected ray from distorted normal, then projects ray onto spheres 60 and 25 feet from reflector. Finally, it writes the intersection onto file 10.
  • step 28 describes the shape of the reflection surfaces. Given x,y,s, it returns z.
  • a call to ZVAL takes a x- and y- coordinate along with 8 coefficients S and returns the Z value of the reflector. Multiple calls can therefore evaluate dz/dx and dz/dy and find the theoretical surface normal. Two offaxis ellipsoids with a blend area between are used but other shapes may be used.
  • the edge shape function Zl is used on the intervals -94mm to -37mm and 37mm to 94mm. This shape reflects light from the lamp to the high intensity portion of the pattern. Three of the eight coefficients are used to vary this shape.
  • the center shape function Z2 is used on the interval -30.5mm to 30.5mm. It spreads light on a horizontal line across the screen. The remaining five coefficients control this shape.
  • the shape is a smooth blend between Zl and Z2.
  • the functions are chosen arbitrarily to describe a general shape which the designer feels may give a good intensity distribution.
  • the designer then chooses which coefficients to allow to vary. For instance, Zl describes a paraboloid where S(7) is the horizontal angle between-the primary axis and the screen center. The process of choosing functions is therefore trial and error. A function choice is put into ZVAL, and its resultant intensity distribution is found. If the designer likes what he sees, the coefficients are optimized. If not, he tries another shape.
  • NORM finds the unit surface normal at the intersection.
  • REFL finds the unit reflected ray given the incident ray and the distorted normal.
  • CD reads sphere intersections from file 10, finds candela values every 1/2° on 30° x 8° section for both spheres. Filament power is set in line 1020 (2W). If NRAY is less than 49000, cd values are averaged over 1-1/2° x 1-1/2° area for each point.
  • PERF compares model cd values to SAE spec. Returns a performance index for the given configuration.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
EP83302633A 1983-05-10 1983-05-10 Kraftfahrzeugscheinwerfer mit Optik enthaltendem Reflektor Expired EP0125353B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DE8383302633T DE3380703D1 (en) 1983-05-10 1983-05-10 Automotive headlight having optics in the reflector
EP83302633A EP0125353B1 (de) 1983-05-10 1983-05-10 Kraftfahrzeugscheinwerfer mit Optik enthaltendem Reflektor

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EP83302633A EP0125353B1 (de) 1983-05-10 1983-05-10 Kraftfahrzeugscheinwerfer mit Optik enthaltendem Reflektor

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EP0125353A1 true EP0125353A1 (de) 1984-11-21
EP0125353B1 EP0125353B1 (de) 1989-10-11

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0214595A2 (de) * 1985-08-30 1987-03-18 GTE Products Corporation Lampenreflektor
EP0225313A2 (de) * 1985-12-04 1987-06-10 Zizala Lichtsysteme GmbH Fahrzeugleuchte
FR2720478A1 (fr) * 1994-05-26 1995-12-01 Valeo Vision Miroir pour dispositif d'éclairage ou de signalisation de véhicule automobile, particulièrement adapté à un dépôt de vernis.

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3492474A (en) * 1966-12-02 1970-01-27 Koito Mfg Co Ltd Reflector with compound curvature reflecting surface

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3139943A1 (de) * 1981-09-29 1983-04-14 Robert Bosch Gmbh, 7000 Stuttgart Scheinwerfer, insbesondere scheinwerfer fuer kraftfahrzeuge

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3492474A (en) * 1966-12-02 1970-01-27 Koito Mfg Co Ltd Reflector with compound curvature reflecting surface

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0214595A2 (de) * 1985-08-30 1987-03-18 GTE Products Corporation Lampenreflektor
EP0214595A3 (de) * 1985-08-30 1990-01-24 GTE Products Corporation Lampenreflektor
EP0225313A2 (de) * 1985-12-04 1987-06-10 Zizala Lichtsysteme GmbH Fahrzeugleuchte
EP0225313A3 (en) * 1985-12-04 1989-05-03 Karl Zizala Metallwarenfabrik Vehicle lights
FR2720478A1 (fr) * 1994-05-26 1995-12-01 Valeo Vision Miroir pour dispositif d'éclairage ou de signalisation de véhicule automobile, particulièrement adapté à un dépôt de vernis.

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DE3380703D1 (en) 1989-11-16
EP0125353B1 (de) 1989-10-11

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