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1ProductDesignCommunicationVehicle:VolvoXC90Lamp:V526RLUpdatedateI1ProductDesignSummary

ProjectintroductionStyleandlayoutExplosiveviewOpticalSolutionThermalandcondensationVibrationsimulationMechanicalsimulationIsostatismProcessManufacturabilityElectronicsSummary

ProjectintroductionProjectintroductionDesignevolution:Expertise2011.11RFQ:2011.11-----2012.7PH1:2012.8-------2013.2PH2:2013.3-------2013.8SidereflexProjectintroductionDesignevoStyleandlayoutTail(21Leds)Fresnelandmicro-prismSide-marker(22Leds)Fresnelandmicro-prismSide-reflexStop(15Leds)FresnelandcubeinnerlensReverse(PSX24Bulb)TI(12Leds)FresnelandcubeinnerlensFog(3Leds)Fresnelandcubeinnerlens718mmStyleandlayoutTail(21Leds)SiExplosiveviewandsectionsExplosiveviewandsectionsOpticalSolutionOpticalSolutionOpticalSolutionFresnel+MicroprismsolutionForconstantopticalaspectofTailandSide-marker.OpticalSolutionFresnel+MicrOpticalSolutionFresnel+IcescreenForStop-TI-Fogfunction.FresnelscreenIcescreen50cm2forSAEregulation(Stop)50cm2forSAEregulation(TI)100cmbetweenFogandStopFogOpticalSolutionFresnel+IceOpticalSolutionP24WBulbPSX24WforReverseFunction(mountinginYdirection)15mmheightOpticalSolutionP24WBulbPSX24ThermalandcondensationBulborLEDLEDRthFunctionDissipatedPowerat13.5V(W)SimulationTestat60°CPSX24W*Reverse18.2W5minon/5minoff24WContinuouslyonThistestistosimulatetheimpactofthePSX24Wbulbtoallothercomponents.ThermalandcondensationBulboThermalandcondensationPC,temperaturelimit150°C:NOKSolutionistomakeShinymetallizationonrearsurfaceofmainbezelThermalandcondensationPC,tThermalandcondensationPMMA,temperaturelimit105-110°C:NOKSolutionistoChangematerialofstopscreentoPMMA-HToradjustFluxofPSX24Wbulb.ThermalandcondensationPMMA,ThermalandcondensationSmallriskyarea,it’sok.PMMA,temperaturelimit105-110°C:NOKThermalandcondensationSmallThermalandcondensationPC,temperaturelimit150°C:NOKSmallriskyarea,it’sok.ThermalandcondensationPC,tThermalandcondensationTail/SMPCBAddSMPCBStopLEDsPCBTILEDsPCBDriverboardThermalandcondensationTail/SThermalandcondensationSimulation20:

60℃,SAE,TAIL,SM,STOP,TI,PmaxThermalandcondensationSimulaThermalandcondensationGivenareaiscoldareaandtheairvelocityisverylowhere.Wemakeagore-texpadtosolvethisproblemThermalandcondensationGivenThermalandcondensationSimulationteamsproposetoincreasethegapat5mmMin.asthestylelimit,wekeepcurrentdefinition.ThermalandcondensationSimulaVibrationMECHANICALSIMULATIONFenderModalHarmonicPSD

TrunkModalHarmonicPSD

SlammingVibrationsimulationVibrationFenderVibrationsimulationVibrationsimulationVibrationsimulation6-screwstoincreasetheconnectionbetweenMainmaskandhousingLotsoflocationdottodecreasethe“L”Addre-enforceribonhousingtoincrease“A”Vibrationsimulation6-screwstVibrationsimulationMechanicalSimulationObjective:Context:CheckfrequencyonthelampassemblyCheckfirstfrequencyTools:Referencedoc:Criteria:ANSYS13SP2VibrationmethodologyV3VibrationMaterialV9Firstfrequency>100HzSecondfrequency>120HzResultsandconclusion:Thefirstfrequencyis72Hz.

Contactriskbetweenmainbezelandlens,mainbezelandsidemarkerKORecommendations:AddcontactsbetweenblackbezelandhousingMode172HzMode279HzVibrationsimulationMechanicalUpdatedate

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23VibrationsimulationStress<fatiguelimitof21MPablackbezelmainbezelMaxstressatcontactsurfaceUpdatedateI23VibrationsimuVibrationsimulationPenetration:7.5-3.5-0.7=3.3mmlensandmainbezelGap=0.7mmContactriskinYdirection,visibleGap=3.5mmPenetration:7.5-0.7-1.4=5.4mmsidemarkerandmainbezelVibrationsimulationPenetratiomechanicalsimulationSimulationtarget:1.EnsureRLresisttotheclampingeffort2.EnsureRLdisplacement.

Applythetorqueof6N.MontheRLscrewfixing1)Applyadisplacementof+/-1.5mmonRLtrunkbottomscrewfixing

2)ChecktheVon-Misesstress(mechanicalresistance)mechanicalsimulationSimulatimechanicalsimulationAddribsonHousingIncreaselocalareathicknessfrom2.5mmto3mmlocalAddribsonHousingIt’sokaftermodificationIt’sokaftermodificationmechanicalsimulationAddribsmechanicalsimulationDisplacementresultmechanicalsimulationDisplacemIsostatismA1A2AdjustedscrewsA3B1B2C1IsostatismA1A2AdjustedscrewsHalf-BCCBBCBAauxiliary-ABIsostatismHalf-BCCBBCBAauxiliary-ABIsostIsostatismHalf-B,CBAHalf-B,CAAIsostatismHalf-B,CBAHalf-B,CIsostatismBCCAAAABCCAAAAAACBBIsostatismBCCAAAABCCAAAAAACBBPlsfindtheinnercomponentsfixationasbelow:ProcessStep-1HousingAssem(WithHarness,gasket,screws,P24WbulbsCP)Step-2WithStopandTIFresnelAssem+Reversereflector(PCBsandFresnelscreens,reversereflector)Step-3WithBackbezelAssem(Backbezel,Tailblade,Sidemarker,PCBsandharness)Step-4WithMainbezelAssem(Mainmask,StopandTIscreen,Reflexreflector)Step-5WithLens(Hot-plateweldingprocess)PlsfindtheinnercomponentsManufacturabilityLensHousingsMainbezelAsimagesshownabove,therearebigdeflectiononLens,HousingandMainbezel.wecanonlyimproveitbymoldadjustment(cooling,adjustingJigs,moldadjustment…..)ManufacturabilityLensHousingsMManufacturabilityWetakemuchtimeadjustingthicknessofMainbezel.Baseonitsstructuredefect,thecomponentstillhavemuchriskonWeldinglines,airtrapsandsinkmark.ManufacturabilityWetakemuchManufacturabilityEjectorOriginalstateejectorstateTakethelensbymanipulatorExtractdirectionManufacturabilityEjectorOriginManufacturabilityThreeslidersforReversereflector.SliderforBulbmountinginYdirectionSlider-TopistoavoidopticalsurfacelosingSlider-BottomistoavoidopticalsurfacelosingManufacturabilityThreeslidersManufacturabilityGeneralthickness5mmFormassivelightaspectofSidemarker.Slidertomoldsideopticalandlocationarea.Micro-opticalfeasibilityneedtobeconfirmedwithDBM.ManufacturabilityGeneralthickElectronicsVerysmallsizeforthisPCBElectronicsVerysmallsizeforUpdatedate

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39ProductDesignCommunicationVehicle:VolvoXC90Lamp:V526RLUpdatedateI1ProductDesignSummary

ProjectintroductionStyleandlayoutExplosiveviewOpticalSolutionThermalandcondensationVibrationsimulationMechanicalsimulationIsostatismProcessManufacturabilityElectronicsSummary

ProjectintroductionProjectintroductionDesignevolution:Expertise2011.11RFQ:2011.11-----2012.7PH1:2012.8-------2013.2PH2:2013.3-------2013.8SidereflexProjectintroductionDesignevoStyleandlayoutTail(21Leds)Fresnelandmicro-prismSide-marker(22Leds)Fresnelandmicro-prismSide-reflexStop(15Leds)FresnelandcubeinnerlensReverse(PSX24Bulb)TI(12Leds)FresnelandcubeinnerlensFog(3Leds)Fresnelandcubeinnerlens718mmStyleandlayoutTail(21Leds)SiExplosiveviewandsectionsExplosiveviewandsectionsOpticalSolutionOpticalSolutionOpticalSolutionFresnel+MicroprismsolutionForconstantopticalaspectofTailandSide-marker.OpticalSolutionFresnel+MicrOpticalSolutionFresnel+IcescreenForStop-TI-Fogfunction.FresnelscreenIcescreen50cm2forSAEregulation(Stop)50cm2forSAEregulation(TI)100cmbetweenFogandStopFogOpticalSolutionFresnel+IceOpticalSolutionP24WBulbPSX24WforReverseFunction(mountinginYdirection)15mmheightOpticalSolutionP24WBulbPSX24ThermalandcondensationBulborLEDLEDRthFunctionDissipatedPowerat13.5V(W)SimulationTestat60°CPSX24W*Reverse18.2W5minon/5minoff24WContinuouslyonThistestistosimulatetheimpactofthePSX24Wbulbtoallothercomponents.ThermalandcondensationBulboThermalandcondensationPC,temperaturelimit150°C:NOKSolutionistomakeShinymetallizationonrearsurfaceofmainbezelThermalandcondensationPC,tThermalandcondensationPMMA,temperaturelimit105-110°C:NOKSolutionistoChangematerialofstopscreentoPMMA-HToradjustFluxofPSX24Wbulb.ThermalandcondensationPMMA,ThermalandcondensationSmallriskyarea,it’sok.PMMA,temperaturelimit105-110°C:NOKThermalandcondensationSmallThermalandcondensationPC,temperaturelimit150°C:NOKSmallriskyarea,it’sok.ThermalandcondensationPC,tThermalandcondensationTail/SMPCBAddSMPCBStopLEDsPCBTILEDsPCBDriverboardThermalandcondensationTail/SThermalandcondensationSimulation20:

60℃,SAE,TAIL,SM,STOP,TI,PmaxThermalandcondensationSimulaThermalandcondensationGivenareaiscoldareaandtheairvelocityisverylowhere.Wemakeagore-texpadtosolvethisproblemThermalandcondensationGivenThermalandcondensationSimulationteamsproposetoincreasethegapat5mmMin.asthestylelimit,wekeepcurrentdefinition.ThermalandcondensationSimulaVibrationMECHANICALSIMULATIONFenderModalHarmonicPSD

TrunkModalHarmonicPSD

SlammingVibrationsimulationVibrationFenderVibrationsimulationVibrationsimulationVibrationsimulation6-screwstoincreasetheconnectionbetweenMainmaskandhousingLotsoflocationdottodecreasethe“L”Addre-enforceribonhousingtoincrease“A”Vibrationsimulation6-screwstVibrationsimulationMechanicalSimulationObjective:Context:CheckfrequencyonthelampassemblyCheckfirstfrequencyTools:Referencedoc:Criteria:ANSYS13SP2VibrationmethodologyV3VibrationMaterialV9Firstfrequency>100HzSecondfrequency>120HzResultsandconclusion:Thefirstfrequencyis72Hz.

Contactriskbetweenmainbezelandlens,mainbezelandsidemarkerKORecommendations:AddcontactsbetweenblackbezelandhousingMode172HzMode279HzVibrationsimulationMechanicalUpdatedate

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61VibrationsimulationStress<fatiguelimitof21MPablackbezelmainbezelMaxstressatcontactsurfaceUpdatedateI23VibrationsimuVibrationsimulationPenetration:7.5-3.5-0.7=3.3mmlensandmainbezelGap=0.7mmContactriskinYdirection,visibleGap=3.5mmPenetration:7.5-0.7-1.4=5.4mmsidemarkerandmainbezelVibrationsimulationPenetratiomechanicalsimulationSimulationtarget:1.EnsureRLresisttotheclampingeffort2.EnsureRLdisplacement.

Applythetorqueof6N.MontheRLscrewfixing1)Applyadisplacementof+/-1.5mmonRLtrunkbottomscrewfixing

2)ChecktheVon-Misesstress(mechanicalresistance)mechanicalsimulationSimulatimechanicalsimulationAddribsonHousingIncreaselocalareathicknessfrom2.5mmto3mmlocalAddribsonHousingIt’sokaftermodificationIt’sokaftermodificationmechanicalsimulationAddribsmechanicalsimulationDisplacementresultmechanicalsimulationDisplacemIsostatismA1A2AdjustedscrewsA3B1B2C1IsostatismA1A2AdjustedscrewsHalf-BCCBBCBAauxiliary-ABIsostatismHalf-BCCBBCBAauxiliary-ABIsostIsostatismHalf-B,CBAHalf-B,CAAIsostatismHalf-B,CBAHalf-B,CIsostatismBCCAAAABCCAAAAAACBBIsostatismBCCAAAABCCAAAAAACBBPlsfindtheinnercomponentsfixationasbelow:ProcessStep-1HousingAssem(WithHarness,gasket,screws,P24WbulbsCP)Step-2WithStopandTIFresnelAssem+Reversereflector(PCBsandFresn