Project 2
AUTOMOTIVE LIGHTING SYSTEM DESIGN
PROJECT 2
CANDIDATE : AKASH PATIL
AIM
To create a tail lamp from the given Class-A surface by following all the design parameters with attachment
features, Positive mounting points and ECE (Economic Commission of Europe) regulations.
LENSE A INPUT
Given CLASS A surface.
GUIDELINES/SPECIFICATION FOR DESIGN:
CREATE COMPLETE TAIL LAMP USING HOT PLATE WELDING SECTION
-Lens Rib height - MINIMUM 8-10 mm
-Interference - 3 mm
-Thickness of Lens - 2.5 mm
-Housing Thickness - 2 mm
-Reflector Thickness - 2 mm
-Boss - M4X10 SCREW
-Positive Mounting for Lamp - M5 SCREW
-Create Wiring harness with wire routing
-Create Clip Mounting and Stud Mounting Features
-Prepare the Assembly and the Child Part drawing for the tail lamp
AUTOMOTIVE LIGHTING SYSTEM
The lighting system of a motor vehicle consists of lighting and signaling devices mounted to or integrated
into the front, rear, sides, and in some cases the top of a motor vehicle. They illuminate the road ahead for
the driver and increase the vehicle's visibility, allowing other drivers and pedestrians to see its presence,
position, size, direction of travel, and its driver's intentions
The colour of light emitted by vehicle lights is largely standardized by established conventions, first codified
in the 1949 Geneva Convention on Road Traffic and later specified in the 1968 United Nations Vienna
Convention on Road Traffic.
For the rear of a vehicle is provided by rear position lamps (also called tail lamps or tail lights). These are
required to produce only red light and to be wired such that they are lit whenever the front position lamps
are lit, including when the headlamps are on. Rear position lamps may be combined with the vehicle's stop
lamps or separate from them. In combined-function installations, the lamps produce brighter red light for
the stop lamp function and dimmer red light for the rear position lamp function.
LENSE A
In lens , there are 2 parts
- Red lense.
-Clear lense.
Red Lens is used for Tail and Stop Light, Clear Lens is used for Turn Indicator and Reverse lights.
MATERIAL : PMMA (POLY METHLY METHA CRYLATE)
PMMA is a strong, tough, and lightweight material, which is less than half that of glass. It also has good
impact strength, higher than both glass and polystyrene. It has a density of 1.17–1.20 g/cm3. PMMA
transmits up to 92% of visible light (3 mm thickness), and gives a reflection of about 4% from each of its
surfaces due to its refractive index (1.4905 at 589.3 nm) and PMMA ignites at 460 °C (860 °F).
CREATION OF LENSE:
Use ROUGH OFFSET command to get smooth c CLASS A surface.
TOOLING AXIS
There are two tooling axis.
-main tooling axis.
-slider tooling axis.
-Lense will clear in main tooling axis whereas the wield track requires 2 tooling axis where the top side of
wield track will clear in slider axis and remaining track in main tooling axis.
DRAFT ANALYSIS FOR LENSE
-REPRESENTATION OF CLEARANCE OF WEILD TRACK IN 2 TOOLING AXIS
LENSE SPLIT & INSERT MOLDING
INSERT MOLD SLOT CREATION
INSERT MOLDING CUT SECTION
MANUFACTURING OF LENSE
Lens is manufactured by injection molding process but exact process is called as "Insert molding or 2K
Molding/2 shot molding "('2K' stands for German word 'Zwei Komponenten' in English 'Two component').
In Insert molding/2K Molding- Initially, an insert part is injection molded, which is clear lens in the tail lamp
case and that molded part(Clear Lens) is used as an insert in other cavity, onto which the other part is
formed by injection molding process.
DRAFTING OF LENSE
REFLECTORS
Reflectors are the internal part of a tail lamp unit, reflectors are the part which reflects the light of the bulb
fitted into the tail lamp unit. Reflectors are shiny in appearance which helps them make more refractive to
enhance the light. Reflectors shape are made of a parabola. Parabolic reflectors gather the light from the
focus of the reflector and return it in a concentrated beam in the direction the reflector is facing. This
concentrated beam of light can be directed to the horizon and can be manipulated to provide a very useful
light.There are three different reflectors.
-Tail and Stop Light reflector
-Turn indicator Light reflector
-Reverse Light reflector
CONIC SKETCH FOR REFLECTOR PARABOLA
STOP REFLECTOR
TURN REFLECTOR
REVERSE REFLECTOR
MATERIAL
Tail lamp Reflectors are made of Polycarbonate. Polycarbonate are strong, tough materials, including
temperature resistance, impact resistance and optical properties. Polycarbonate has a glass transition
temperature of about 147 °C
B-FEATURES & FLUTES IN REFLECTOR
SCREW BOSSES & VENT HOLES
FLUTES
VENT HOLES are provided for the purpose of helping to reduce condensation in the lamp unit.Plastic cap
vents to block water and dust ingress inside the lamp are called vent caps. Headlamps and tail lamps have
to cope with environmental conditions that change every day. What’s more, they have to be protected
against dust, dirt, deposits, and condensation if they are to work effectively and guarantee drivers a clear
view at all times. Various options are available to automobile manufacturers and suppliers for removing
moisture from headlamps. When selecting a venting membrane as an option, the solution must be able to
equalize pressure within the headlamp housing, form an effective barrier against dirt and water ingress,
and be able to reduce condensation.
CONDENSATION
In regard to car's Head/Tail lights, the phenomenon takes place when the outside air is cooler than the air
inside the lighting assembly. The warmth of the bulbs paired with the cold weather can create the perfect
environment for condensation, leading to the formation of water droplets inside the headlights.
Bulbs used in the lamp are:
Stop Function- PR21/5W
Turn Function- PY21W
Reverse Function- W16W
ECE REGULATION FOR LIGHTING SYSTEM
-According o ECE R48,R23,R7,R6 ,The maximum height at which the tail lamp should be position is 1500mm
from the ground plane, the ground plane is taken at 500mm away from the axle centre
-And from the centre it should be minimum 600mm.
ECE Regulations
For Tail function- Vertically it should be visible 15 Degrees upward and downward.
For Turn function- Vertically it should be visible 15 Degrees upward and downward.
MATERIAL
Polycarbonate(PC).
To make reflectors reflective, The Aluminum coating is done over the reflectors, in which the aluminum is
heated and air blown over the reflectors in a close heated chamber.
DRAFT ANALYSIS FOR REFLECTOR
REFLECTOR DRAFTING
HOUSING
Housing is a part which covers the reflectors and joins with the lens. Housing contains the bulb holders and
seating area in which the bulb fits, It contains the reflector mounting points to mount the reflector on the
housing and It has many mounting features through which the light unit can be mounted on the vehicle.
Material
Housing made of ABS(Acrylonitrile butadiene styrene). Housing is a unit which holds all the parts of a light
unit and mounts on the vehicle. So the housing should be strong and sturdy and ABS is the perfect material
to make housing of a tail lamp unit.
SCREW BOSS CUT SECTION
AIR VENT CUT SECTIONALL
B FEATURES
POSITIVE MOUNTING
DRAFT ANALYSIS
WIRING HARNESS:
Wiring harness is electrical connection between electrical equipment to the electric source like like
terminals and Wiring harness is the wiring structure that protects the lights from outside environment and
water
Grommet was created so that the wiring can be separated from inside the housing and from outside.
The water slides and stops at the grommet and prevents the water entering the housing.
A routing feature is created to keep the wires held in place and helps the wires get not tangled
Given connector have 6 poles and we have 7 poles for the lights , we have common wire for earth which is
black
Here, Tail and stop function have same pole.
DRAFTING PICS
Conclusion
Thus, the tail lamp was designed with the given surface by following required design guidelines, parameters and ECE
regulations and Assembly and Child parts drawings are also created