1、Update date I 1Product Design CommunicationVehicle: Volvo XC90Lamp: V526 RLSummaryProject introductionStyle and layoutExplosive view Optical SolutionThermal and condensationVibration simulationMechanical simulationIsostatismProcessManufacturabilityElectronicsProject introductionDesign evolution:Expe

2、rtise 2021.11 RFQ: 2021.11-2021.7 PH1:2021.8-2021.2 PH2:2021. 3-2021.8Side reflexStyle and layoutTail(21Leds)Fresnel and micro-prismSide-marker(22Leds)Fresnel and micro-prismSide-reflexStop(15Leds)Fresnel and cube inner lensReverse(PSX24 Bulb)TI(12Leds)Fresnel and cube inner lensFog(3Leds)Fresnel an

3、d cube inner lens718mmExplosive view and sectionsOptical SolutionOptical SolutionFresnel + Micro prism solution For constant optical aspect of Tail and Side-marker.Optical SolutionFresnel + Ice screen For Stop-TI-Fog function.Fresnel screenIce screen50cm for SAE regulation(Stop)50cm for SAE regulati

4、on(TI)100cm between Fog and StopFogOptical SolutionP24W BulbPSX24W for Reverse Function(mounting in Y direction)15mm heightThermal and condensationBulb or LEDLED RthFunctionDissipated Power at 13.5 V (W) SimulationTest at 60C PSX24W*Reverse18.2W5 min on/ 5 min off24 W Continuously onThis test is to

5、simulate the impact of the PSX24W bulb to all other components.Thermal and condensationPC, temperature limit 150 C: NOKSolution is to make Shiny metallization on rear surface of main bezelThermal and condensationPMMA, temperature limit 105-110 C: NOKSolution is to Change material of stop screen to P

6、MMA-HT or adjust Flux of PSX 24W bulb.Thermal and condensationSmall risky area, its ok.PMMA, temperature limit 105-110 C: NOKThermal and condensationPC, temperature limit 150 C: NOKSmall risky area, its ok.Thermal and condensationTail/SM PCBAdd SM PCBStop LEDs PCBTI LEDs PCBDriver boardThermal and c

7、ondensationSimulation 20 : 60 , SAE, TAIL, SM, STOP,TI, PmaxThermal and condensationGiven area is cold area and the air velocity is very low here . We make a gore-tex pad to solve this problemThermal and condensationSimulation teams propose to increase the gap at 5mm Min. as the style limit , we kee

8、p current definition.Vibration MECHANICAL SIMULATION Fender Modal Harmonic PSD Trunk Modal Harmonic PSD Slamming Vibration simulationVibration simulationVibration simulation6-screws to increase the connection between Main mask and housing Lots of location dot to decrease the “LAdd re-enforce rib on

9、housing to increase “AVibration simulationMechanical SimulationObjective:Context:Check frequency on the lamp assemblyCheck first frequencyTools:Reference doc:Criteria:ANSYS 13 SP2Vibration methodology V3Vibration Material V9First frequency100 HzSecond frequency120HzResults and conclusion:The first f

10、requency is 72Hz.Contact risk between main bezel and lens , main bezel and side markerKORecommendations:Add contacts between black bezel and housingMode 1 72HzMode 2 79HzUpdate date I 23Vibration simulationStress fatigue limit of 21MPablack bezelmain bezelMax stress at contact surface Vibration simu

11、lationPenetration :7.5-3.5-0.7=3.3mm lens and main bezelGap=0.7mmContact risk in Y direction, visibleGap=3.5mmPenetration :7.5-0.7-1.4=5.4mm side marker and main bezelmechanical simulation Simulation target: 1.Ensure RL resist to the clamping effort 2.Ensure RL displacement. Apply the torque of 6N.M

12、 on the RL screw fixing 1) Apply a displacement of +/-1.5mm on RL trunk bottom screw fixing 2)Check the Von-Mises stress (mechanical resistance)mechanical simulationAdd ribs on HousingIncrease local area thickness from 2.5mm to 3mm localAdd ribs on HousingIts ok after modificationIts ok after modifi

13、cationmechanical simulationDisplacement resultIsostatismA1A2Adjusted screws A3B1B2C1Half-BCCBBCBAauxiliary-ABIsostatismIsostatismHalf-B ,CBAHalf-B ,CAAIsostatismBCCAAAABCCAAAAAACBBPls find the inner components fixation as below:ProcessStep-1 Housing Assem(With Harness, gasket, screws, P24W bulbs CP)

14、Step-2 With Stop and TI Fresnel Assem+ Reverse reflector (PCBs and Fresnel screens ,reverse reflector)Step-3 With Back bezel Assem(Back bezel, Tail blade, Side marker, PCBs and harness)Step-4 With Main bezel Assem(Main mask ,Stop and TI screen, Reflex reflector)Step-5 With Lens(Hot-plate welding pro

15、cess)ManufacturabilityLensHousingsMain bezelAs images shown above ,there are big deflection on Lens, Housing and Main bezel. we can only improve it by mold adjustment(cooling,adjusting Jigs, mold adjustment.)ManufacturabilityWe take much time adjusting thickness of Main bezel. Base on its structure

16、defect, the component still have much risk on Welding lines, air traps and sink mark.ManufacturabilityEjectorOriginal stateejector stateTake the lens by manipulator Extract directionManufacturabilityThree sliders for Reverse reflector.Slider for Bulb mounting in Y directionSlider-Top is to avoid optical surface losingSlider-Bottom i