Project 2

Report for Tail Lamp

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

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.

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.

• Created Clear Lens for Turn Indicator and Reverse Light and performed

LENS WELD TRACK:- WE TAKE A SURFACE AND SKETCH OVER THAT LIKE ROUFGH SKETCH LIKE WELD TRAKE THEN SWEEP THAT AND GIVE FILLETS. NOW TAKE INTERSECTION OF BOTH SURFACES AND EDIT BY SPLINE TO MAKE GREAT WELD TRACK THEN SPLIT THE WELD INTERSECTION AND SWEEP ALONG TOOLING AXIS AND SLIDER AXIS. THEN THICK THE SURFACE AND UNION TRIM EITH YOUR LENS.

 REFLECTORS- REFLECTORS ARE USED TO SPREADING LIGHT IN ANGLES. AS WELL AS IN VERTICALLY AT 45 AND 80 DEGREE RESPECTIVUILY AND 15 DEGREE HORIZONTALLY. IN REFLECTOR WE MAKE FLUTES FOR REFLECTING LIGHT IN DIRECTIONS.. IN REFLECTER WE USE SCREW BOSSES AS B FEATURE FOR HOLDING REFLECTOR WITK HOUSING. ATTECH BULB WITH REFLECTOR .

There are three different reflectors

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

PROCESS OF MAKING FLUTES:- EXTRACT SURFACE THEN UNTERIN BOTH SURFACE TAKE INTERSECTION OF BOTH SURFACE AFTER THAT TAKE A POINT ON INTERECTION AND CREAT A LINE ALONG THE TOOL AXIS AND GIVE SUPPORT AS A REFLECTOR SURFACE THEN SWEEP AND USE POWER COPY AGAIN AND AGAIN.

• 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.

• HOW WE MAKE HOSUING:-

• FIRST WE OFFSET LENS A MODIFIED SURFACE AS 15MM . AND WE OFFSET REFLWCTORS SURFACE TO 4.5 MM EACH THEN THE HELP OF EACH OFFSET SURFACE WE MAKE HOUSING A SURFACE. NPW WE OFFSET HOUSING A SURFACE AT 2.5MM AND GET HOSING B SURFACE THEN WE MAKE C SURFACE AND CREAT HOUSING SOLID BODY.
• THEN WE ADDED B FEATURS IN HOSING BY THE AXIS SYSTEM. AND WE ALSO MAKE FLANGES.THERE ARE MANY B FEATURES IN HOUSING LIKE VENT CAP,STUD,M4 SCREW, AND FLAGE , WIRING SUPPORT ANDBULB SEATING AREA.

HOUSING WELD TRACK:- WE CREAT A SKETCH ON LENS WELD TRACK AND AND EXTRACT THE LENS WELDTRACK SURFACE THEN OFFSET BOTH SURFACE AT 0.75MM AND TAKE BOUNDARY AND OFFSET BOUNDARY AT 3MM BY PARELLEL CURVE AND GIVE SUPPORT AS OFFSET SURFACE THEN SWEEP THE SKETCH ALONG THE PARELLEL CURVES.

 WIRING HARNESS:-  WE CREAT A GROMMET AND TAKE B FEATURE INPUT SHOCKET MAKE WIRING SUPPORT AND BY THE HELP OF LINE AND SPLINE WE MAKE WIRES THEN JOIN THE WIRES AND CONIC ALL OF THEN THEN WE USE GUIDE AND RADIUS SWEEP OPTION TO MAKE LIKE WIRE. AND CONNECTED WITH SHOCKET THROUGH GROMMET OUR WIRING LOOK LIKE THID IMG IS GIVEN BELOW:-

MOUNTING POINTS ARE SHOWNS IN SOME IMAGES:-

DRAFTINGS:-

ASSEMBLY DRAFTING:-

REFLECTOR DRAFTING:-

LENS DRAFTING:-

 HOUSING DRAFTING:-

SOME OUTLOOK OF TAIL LIGHT:-

SOME OUT LOOKS OF TAIL LAMP:-