Project 2

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Design of Tail lamp for Production vehicle

AIM

The aim of the project is to design a complete assembly of tail lamp considering all the parameters with lens, reflector, housing, wiring harness and other features on the housing to fix the  tail lamp assembly with vehicle. CATIA V5 is used for the complete design of tail lamp assembly project.

INTRODUCTION

Tail lamp is the light function which shows the presence of vehicle mostly at night. It is one of major safety feature for vehicle. Tail lamp will have 3 functions at least , tail/stop, reverse and turn signal, Tail/stop is present in red colour lens and reverse and turn is present in clear lens. The lens and housing of the lamp is designed as per industry standard by checking all the regulations, While design of reflector is done in such a way that no light leakage happens inside the casing of light. Anti fog coating is done at the lens so that condensation does not happen and in reflector metalization is done for better reflection of light. Bulb are standard part.

Steps involved in manufacturing of the Tail lamp assembly are shown below:-

1. Designing the solid body of the lens along with the welding track.
2. Determing the shape and positions of the tail stop, yutn and reverse reflector.
3. Desiging the solid body of thr reflectors
4. Desinging the solid body of the housing for the lens along with welding track for the housing.
5. Make screw bosses for reflector and housing.
6. creation of red and clear lens
7. presentation of final product
8. Drafting of tail lamp assembly
9. Bill of material
   
   
   Design of the lens
   
   

   This the lens A surface , after getting the A surface first need to check the quality of the surface, if it has a irregular surface then need to correct the surface and make a good quality surface. The tooling axis of the input has to be determine before proceding and check whether it is clearing  having the draft or not.

   In this lens A surface was not at all satisfactory so need to main the surface and create the B surface for the same, after creating the B surface C surface need to be created to close the boundry which shown below with tooling direction
   
   

   Design reflector for the assembly

   Tail lamp consist of 3 major function:-

   1. Tail/stop function 
   2. Turn signal
   3. Reverse function

   Tail/stop function is in red lens and tail is used with headlight on time while the stop function activate when the driver press the brake padle, turn signal on when driver activate the switch while make a right or left turn and turn signal also works when hazard lamp is switched on. Reverse light turns on when the reverse gera is engaged.

   To design the reflectors first we need to create the parabola at the back side of the parabola poitns are given and then the focal points are given so that the bulbs are placed then in the disired the parabola are trimmed to create the reflectors. Parameters and relation features are used to specify the diameter of the parabola so that in future some one wants to modify the parabola they can easily do that.

   Next step is to add bulb in the focal points of the reflectors. Bulbs are Bop poarts so need to add the bulbs in the master file then with axis to axis translation they are placed in the reflectors. Bulbs which are used are speified below

   1. Tail/stop function:- W21/5W BULB
   2. Turn signal:- WY21W BULB
   3. Reverse function:- W16W BULB

   Along with bulb , bulb holders , seating area were also imported. With the help of bulb seating area the bulbs are fixed to the housing with the help of union trimming.

   After the creation of the reflectors It is placed at the required position on the housing and it is the most important step in designing the reflectors,As per the industry certain rules has to be followed which are minimum and maximum distance at which each function should be placed by considering all thses factors reflectors were positioned at required position following the industry standards.
   
   

   Design of Housing

   Housing is the most important part of the light design because housing hold all the parts together and get fixed in the BIW surface. The first step of creation of housing is to create master section , projection of surrounding , weilding track of lens solid body were taken into consideration and then sketch was developed by referring to which the housing can be designed 

   Hot plate weilding technique was to be used to attached the housing with the lens to accomodate both lens and housing together.

   While creating the housing many industry factors were taken in consideration to make sure their is no light leakage happening inside the lens.
   
   

   BILL OF MATERIAL

   A bill of material is the list of product used in the assembly , name of part, quantity, any remarks is there or not any assembly can not happen without BOM. The actual reprentation of BOM is shown below.