Project 2

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.

Given Class-A Surface

Guidelines followed to create The Tail Lamp

CREATE COMPLETE TAIL LAMP USING HOT PLATE WELDING SECTION

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

Positive Mounting for Lamp  - M5 SCREW

Create Wiring harness with wire routings

Create Clip Mounting and Stud Mounting Features

Prepare the Assembly and the Child Part drawing for the taillamp

Introduction-

The lighting system of a motor vehicle consists of lighting and signalling devices mounted or integrated at the front, rear, sides, and in some cases the top of a motor vehicle.

LENS

Lens is the outer part of a tail lamp unit which covers the reflectors and housing.

In Lens, there are two parts:

1. Red Lens
2. Clear Lens

Red Lens is used for Tail and Stop Light, Clear Lens is used for Turn Indicator and Reverse lights.

Material-:  PMMA material is used for Tail Lamp, 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/cm^3.   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).

• To create Lens

Here, Rough offset command is used to get a smooth surface.

To create Lens

• Offset the surface for required distance, In this Lens Thickness is maintained 2.5mm
• Created the C-Surface and made a Solid body.
• To make Rib or Welding track, created the sweep on the created welding track sketch, which is inside 11mm from the surface boundry.
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• Created welding track with 1.5 draft angle for easy tooling.
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• Created Clear Lens for Turn Indicator and Reverse Light and performed Draft Analysis.
• Insert Molding Section

   

  

  REFLECTOR

  Reflectors are the internal part of a tail lamp unit, reflectors are the part which reflects the light of the bulb fitted into the tai lamp unit. Reflectors are shiny in appearence which helps them make more refractive to enhance the light. Reflectors shape are made of a parabola.

   
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• There are three different reflectors

  • Tail and Stop Light reflector
  • Turn indicator Light reflector
  • Reverse Light reflector

  Material- Tail lamp Reflectors are made of Polycarbonate. Polycarbonates are strong, tough materials, including temperature resistance, impact resistance and optical properties. Polycarbonate has a glass transition temperature of about 147 °C (297 °F).

  • To create reflectors

  The major shape of reflectors are depend upon the Class-A Surface.

  • The shape of reflectors is made with Parabola.
  • To create the reflectors, the sketch is drawn and swept with 3 degrees draft for easy tooling.
  • There are Rollets or Flutes on the reflectors surface to uniformly reflect the light.
• 
• Reflectors have vent cap holes which helps 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. 
• Condesation- 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.
• To reduce Condensation Vent Caps are provoded.
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  • Bulbs used in the lamp are:

    Stop Function- W21/5W 

    Turn Function- W21W 

    Reverse Function- W16W
• • Mounting of Reflectors

  M4x10 Screw Boss

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  • 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.
  • 
  • For Reverse function- Horizontaly- It should be visible 80 Degrees Outward and 45 Degrees Inward.
  • For Turn function- Horizontaly- It should be visible 80 Degrees Outward and 45 Degrees Inward.

    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.

    
  • Housing has a welding track which joins with the Lens welding track.
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  • Housing has Reflector Mounting points
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  • It has 3 stud mounting to mount on the BIW panel.
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  • It has Positive mounting of M5 bolts to mount the lamp unit on the vehicle. Positive Mounting Point is where it does not accumulate water in the different weather conditions
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  • Housing Draft Analysis

  • WIRING HARNESS

    Wiring harness is electrical connection between electrical euipments 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.
  • 

  • HOT PLATE WELDING

    Hot plate welding, also called heated tool welding, is a thermal welding technique for joining thermoplastics. A heated tool is placed against or near the two surfaces to be joined in order to melt them. Then, the heat source is removed, and the surfaces are brought together under pressure. Hot plate welding has relatively long cycle times, ranging from 10 seconds to minutes, compared to vibration or ultrasonic welding.

  • HOT PLATE WELDING SECTION
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  • Lens Rib hight - MINIMUM 6-10 MM
  • 
  • Thickness of Lens - 2.5 MM
  • 

  • Housing Thickness - 2 MM

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  • Reflector Thickness - 2 MM

    

  • Prepare the Assembly and the Child Part drawing for the taillamp

    Assembly Drawing

    

    Child Part drawing

    Lens drawing

    
  • housing drawing 
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  • Reflector Drawing
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  • Different Views of Tail Lamp

    Front View

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  • left side view 
  • 
  • right side view 
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  • Rear side view
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  • ISOMETRIC VIEW 
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