Project 1 - - Automotive Lighting

Objective

The aim of this project is to complete 3D modelling of an Rear combinational lamp and perfrom various operations in accordance the industry life cycle . The inputs given are as follow.

Lens Rib hight - MINIMUM 8-10 MM

Interferance - 1.5 MM

Thickness of Lens - 2.5 MM

Housing Thickness - 2 MM

Reflector Thickness - 2 MM

Boss - M4X10 SCREW

Procedures

Tail lamp is basically used to show any vehicle position so one should able to see from distance but as above maintained the intensity is low then it will not be clearly visible and if the intensity is too high then it will be a distraction for the back driver.

Some general material used for the lamp are listed below

PARTS NAMES	MATERIAL
LENS/INNER LENS	PMMA/PC
HOUSING	PP/ABS/ASA
REFLECTOR	PC
BEZEL	PBT/PC
BULB/LED	STANDARD(P21W,P21/5W,PY21W,W5W)

The steps performed to completed the projects are listed below.

Given surfaces

The tooling axis is created for the surface.

Once the tooling axis is done the seal track for the Hot plate welding is to be created. The B & C surfaces are created .

The surfaces are then joined and made as a solid part

Once the lens section is done we are creating the Housing and the reflectors.The seal leg of the housing is been created from the housing .

The lens surface is offseted and the hosuing B surface is created

The surfaces are then joined and made as solid .

Various assembly features are then added to the housing so that the reflector can be attached

Now the reflector is to created for the Lamp.

The reflectors are created with suitable flutes to avoid the bad reflection of the light . The focus of the reflector are made as 25 at inital stages and further increased based upon the geometrical visibility of the Lamp.

For Tail function bulb details:-

For tail function, P5W can be used (pin type with 5 watts)

For Stop function bulb details:-

For tail function, P21W can be used (pin type with 21 watts)

Mainly tail and stop function, OEM used to keep in same chamber most of the time so P21/5W (dual filament bulb) is being used

flutes are created with the help of powercopy and then trimmed with the relfector surfaces, the same process is followed for all the reflectors and then trimmed .

Once the housing reflectors are done the bulbs are moved to the respective positions with the Bulb socket.The input mounting features are given as below.

Once the Housing is done with the help of the surrounding data provided we are going to make a cord assy that can fulfill all the functions of the lamp.Proper clips and wires should be selected with the help of the PJM & Purchase department.

Once the model is done , the drafting is done by cosnidering the following parts.

1. Mounting coordinates
2. Focal coordinates
3. Pivot to pivot distance
4. Packaging distance
5. Regulation angles
6. Metalizing area’s
7. Anti-fog coating area’s
8. BOM
9. Slider lines
10. Parting line for all parts

Assembly drawing

Housing Drawing

Reflectors

Conclusion

Various parts of an automobile lamps are created in accordance to the regualtions and an proper aseembly is made in CATIA. The parts are then drafted so that it can used by other teams to verify the quality of the parts in the assembly line.