Design optimization of a smooth headlamp reflector to SAE/DOT beam-shape requirements

Narkis E. Shatz; John C. Bortz; Mahendra S. Dassanayake

doi:10.1117/12.368246

6 October 1999 Design optimization of a smooth headlamp reflector to SAE/DOT beam-shape requirements

Narkis E. Shatz, John C. Bortz, Mahendra S. Dassanayake

Proceedings Volume 3781, Nonimaging Optics: Maximum Efficiency Light Transfer V; (1999) https://doi.org/10.1117/12.368246
Event: SPIE's International Symposium on Optical Science, Engineering, and Instrumentation, 1999, Denver, CO, United States

Abstract

The optical design of Ford Motor Company's 1992 Mercury Grand Marquis headlamp utilized a Sylvania 9007 filament source, a paraboloidal reflector and an array of cylindrical lenses (flutes). It has been of interest to Ford to determine the practicality of closely reproducing the on- road beam pattern performance of this headlamp, with an alternate optical arrangement whereby the control of the beam would be achieved solely by means of the geometry of the surface of the reflector, subject to a requirement of smooth-surface continuity; replacing the outer lens with a clear plastic cover having no beam-forming function. To this end the far-field intensity distribution produced by the 9007 bulb was measured at the low-beam setting. These measurements were then used to develop a light-source model for use in ray tracing simulations of candidate reflector geometries. An objective function was developed to compare candidate beam patterns with the desired beam pattern. Functional forms for the 3D reflector geometry were developed with free parameters to be subsequently optimized. A solution was sought meeting the detailed US SAE/DOT constraints for minimum and maximum permissible levels of illumination in the different portions of the beam pattern. Simulated road scenes were generated by Ford Motor Company to compare the illumination properties of the new design with those of the original Grand Marquis headlamp.

Citation Download Citation

Narkis E. Shatz, John C. Bortz, and Mahendra S. Dassanayake "Design optimization of a smooth headlamp reflector to SAE/DOT beam-shape requirements", Proc. SPIE 3781, Nonimaging Optics: Maximum Efficiency Light Transfer V, (6 October 1999); https://doi.org/10.1117/12.368246

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