Deformation compensation design method for automobile light guide strip

Abstract

The invention relates to the technical field of automobile lamp design and manufacturing, in particular to a deformation compensation design method for an automobile light guide strip. The method comprises the following steps: S1, establishing a light guide strip product model; s2, performing mold flow analysis on the light guide strip product model to obtain model deformation data; s3, establishing a light guide strip optical model based on the model deformation data; s4, simulating the light guide strip optical model to obtain a lighting effect defect area; and S5, obtaining a model compensation amount based on the lighting effect defect area, and generating an output model based on the model compensation amount. According to the method, through coupling mode flow analysis and optical simulation, a deformation and lighting effect closed-loop feedback mechanism is constructed, the problem that in the prior art, due to material shrinkage, geometric deformation of the light guide strip is mismatched with optical performance is solved, the production cost is effectively reduced, and the development period is effectively shortened.

Description

Technical Field

[0001] The invention relates to the technical field of automobile lamp design and manufacturing, and in particular to a deformation compensation design method for an automobile light guide strip. Background Art

[0002] In the field of automotive lighting design and manufacturing, light guide strips are the core optical components for achieving uniform lighting and dynamic lighting effects. They are usually made of transparent plastic materials through injection molding, with micron-level prisms or scattering texture structures distributed on the surface, guiding light propagation through the principle of total reflection.

[0003] However, the geometric deformation problem caused by the shrinkage characteristics of plastic materials during the injection molding process has long restricted the optical performance and production efficiency of the product. In the prior art, the dimensional deviation caused by the anisotropy of shrinkage during the material cooling stage will significantly change the light propagation path, resulting in dark areas or bright spots with local light intensity differences exceeding 30%. The industry generally relies on empirical formula pre-compensation and trial-and-error correction, but because regional shrinkage differences are not taken into account, multiple mold trials are often required to meet the lighting efficiency requirements. At the same time, the data splitting problem of mold flow analysis and optical simulation tools is prominent. The macro deformation predicted by mold flow cannot be associated with the deformation of the microscopic optical structure, resulting in a disconnect between the compensation design and the actual lighting efficiency verification. Summary of the invention

[0004] The problem solved by the present invention is that in the design and production of automobile light guide strips, mold flow analysis and optical simulation run independently, resulting in deformation prediction not covering the optically sensitive area and the mold flow analysis compensation design being out of touch with actual light effect requirements.

[0005] The present invention adopts the following technical solution: a deformation compensation design method for an automobile light guide strip, the deformation compensation design method comprising: Step S1, establishing a light guide strip product model; Step S2, performing mold flow analysis on the light guide strip product model to obtain model deformation data; Step S3, establishing a light guide strip optical model based on the model deformation data; Step S4, simulating the optical model of the light guide strip to obtain a light effect defect area; Step S5, obtaining a model compensation amount based on the light effect defect area, and generating an output model based on the model compensation amount.

[0006] Compared with the existing technology, the technical effects achieved by adopting this technical solution are as follows: First, by directly mapping the microstructure deformation data obtained from mold flow analysis to the optical model, it breaks through the limitation of the separation of mold flow and light effect simulation data in traditional methods, so that the compensation design can accurately associate geometric deformation with light intensity distribution; second, the light effect defect area is located based on optical simulation, replacing the traditional method of relying on manual experience to judge the defect position, avoiding the extension of production cycle caused by invalid compensation and reducing production costs.

[0007] Furthermore, step S5 also includes detecting whether the output model meets the standard. If not, rebuilding the light guide strip product model according to the output model, and then returning to step S2.

[0008] Compared with the existing technology, the technical effects achieved by adopting this technical solution are: first, through closed-loop feedback optimization design and iterative updating of the light guide strip product model, the geometric compensation amount is gradually approached to the theoretical optimal value, avoiding the inefficiency caused by repeated modification of the mold in the traditional trial and error method, and improving the design accuracy and reliability; second, by replacing the traditional manual adjustment of product parameters, the time spent on compensation parameter correction is greatly reduced.

[0009] Furthermore, step S2 also includes: performing mold flow analysis on the light guide strip product model based on material parameters and process parameters.

[0010] Compared with the existing technology, the technical effect achieved by adopting this technical solution is as follows: combining material and process parameters for simulation, accurately predicting the deformation trend in actual molding, reducing the prediction deviation caused by lack of experience, and at the same time, predicting and avoiding defects caused by process parameter mismatch in the mold flow stage, thereby reducing the cost of mold trial.

[0011] Furthermore, based on the material parameters and process parameters, a mold flow analysis is performed on the light guide strip product model to select the mold surface temperature and the melt temperature to determine the molding data of the light guide strip product model.

[0012] Compared with the existing technology, the technical effect achieved by adopting this technical solution is: combining the interaction between the melt temperature and the mold surface temperature, accurately simulating the phase change process of the material from the molten state to the solid state, so that the shrinkage deformation prediction error is greatly reduced.

[0013] Furthermore, the mold flow analysis of the light guide strip product model based on the material parameters and process parameters also includes selecting the injection time, the holding time and the holding pressure to determine the melt filling data.

[0014] Compared with the existing technology, the technical effects achieved by adopting this technical solution are as follows: First, by optimizing the matching of injection time and holding pressure, the uniformity of the melt flow front speed is improved to avoid short shots or cavitation defects caused by uneven filling; second, by combining the coupling setting of holding time and holding pressure, the melt cooling shrinkage is effectively compensated, so that the volume shrinkage rate of the light guide strip is effectively improved compared with the traditional method; third, through multi-parameter collaborative analysis, the injection molding process is fully simulated, the molding quality is optimized, and the limitations of single parameter analysis are avoided.

[0015] Furthermore, the material parameters also include material PVT curves and material thermal performance parameters, which are used to perform mold flow analysis on the light guide strip product model.

[0016] Compared with the existing technology, the technical effects achieved by adopting this technical solution are: first, the volume change of the material in the melting-cooling phase change process is quantified based on the PVT curve, thereby reducing the shrinkage prediction error; second, the influence of the local temperature gradient on the microstructure forming is predicted by combining the thermal conductivity of the material with the mold cooling rate; third, for different materials, the mold flow analysis parameters are dynamically adjusted to reduce the adaptation error of the shrinkage compensation amount of the two materials under the same process and reduce the over-compensation rate.

[0017] Furthermore, step S2 also includes: establishing an optical model of the light guide strip according to the refractive index and the surface scattering coefficient.

[0018] Compared with the existing technology, the technical effects achieved by adopting this technical solution are: first, the light path deviation of the deformed light guide strip is quantified by the refractive index, and the surface microstructure defects are evaluated in combination with the scattering coefficient, thereby reducing the prediction error of light intensity uniformity; second, based on optical parameter mapping, the recognition accuracy of the light effect defect area is improved, the area of ​​the compensation area is reduced, and the waste of resources caused by invalid compensation is avoided; third, the impact of deformation on light effect is quantified through optical parameter modeling, replacing the traditional compensation method that only relies on geometric deformation, thereby improving the targetedness of light effect repair.

[0019] Furthermore, in step S3, the optical model of the light guide strip is preprocessed, and the preprocessing includes setting target optical parameters of the optical model of the light guide strip.

[0020] Compared with the existing technology, the technical effect achieved by adopting this technical solution is: clarifying the lighting effect design goal, providing a benchmark for the calculation of the compensation amount, and avoiding the compensation direction deviating from the actual demand.

[0021] Furthermore, step S5 further includes: obtaining light guide parameters after deformation according to the model deformation data, and obtaining model compensation according to the light guide parameters after deformation, the model compensation being: = +k·( - ); in, is the light guiding parameter after deformation, is the target optical parameter, is the compensation parameter, and k is the material-structure coefficient.

[0022] Compared with the existing technology, the technical effects achieved by adopting this technical solution are: first, the efficiency of light intensity uniformity repair is improved by coupling geometric deformation and optical performance through the k value; second, the compensation accuracy is improved by fitting mathematical models for the deformation of the curved surface area of ​​the light guide strip and the nonlinear response of light intensity loss.

[0023] Furthermore, the material-structure coefficient is selected through the luminous flux loss rate, and the luminous flux loss rate calculation formula is: (initial design luminous flux-measured luminous flux) / initial design luminous flux×100%, where the initial design luminous flux is the target luminous flux, and the measured luminous flux is obtained by measuring the output model.

[0024] Compared with the existing technology, the technical effects achieved by adopting this technical solution are: first, according to the measured luminous flux loss rate, the production cost is reduced and the excessive compensation is reduced; second, in view of the performance fluctuations of different batches of the same material, the luminous flux consistency of the light guide strip is improved by controlling the k value; third, the compensation coefficient is dynamically optimized based on the measured luminous flux, solving the problem that the traditional fixed compensation coefficient cannot adapt to different materials and structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A flow chart showing a method for designing a deformation compensation for an automotive light guide strip in this exemplary embodiment; Figure 2 A schematic structural diagram of a car light guide strip in this exemplary embodiment is shown; Figure 3 A schematic diagram showing deformation of an automotive light guide strip in the X direction in mold flow analysis in this exemplary embodiment is shown; Figure 4 A schematic diagram showing deformation of an automotive light guide strip in the Y direction in mold flow analysis in this exemplary embodiment is shown; Figure 5 A schematic diagram showing deformation of an automotive light guide strip in the Z direction in mold flow analysis in this exemplary embodiment is shown; Figure 6 A schematic diagram of a deformed structure of an automobile light guide strip after mold flow analysis in this exemplary embodiment is shown; Figure 7 A schematic diagram showing a structure of compensation adjustment of a car light guide strip in this exemplary embodiment is shown; Figure 8 A comparison diagram of the lighting effects of a car light guide strip before and after deformation in this exemplary embodiment is shown; Fig. 9A deformation-light intensity loss response surface graph of an automotive light guide strip in this exemplary embodiment is shown. DETAILED DESCRIPTION

[0026] Example embodiments will now be described more fully with reference to the accompanying drawings. However, example embodiments can be implemented in a variety of forms and should not be construed as being limited to the examples set forth herein; on the contrary, these embodiments are provided so that the present disclosure will be more comprehensive and complete, and the concepts of the example embodiments are fully conveyed to those skilled in the art. The described features, structures, or characteristics may be combined in one or more embodiments in any suitable manner. In the following description, many specific details are provided to provide a full understanding of the embodiments of the present disclosure. However, those skilled in the art will appreciate that the technical solutions of the present disclosure may be practiced while omitting one or more of the specific details, or other methods, components, devices, steps, etc. may be adopted. In other cases, known technical solutions are not shown or described in detail to avoid obscuring various aspects of the present disclosure.

[0027] In addition, the flowcharts shown in the accompanying drawings are only exemplary and do not necessarily include all the steps. For example, some steps can be decomposed, and some steps can be combined or partially combined, so the actual execution order may change according to the actual situation.

[0028] See also Figure 1-Figure 8 , this embodiment adopts the following technical solution: A deformation compensation design method includes: Step S1, establishing a light guide strip product model; Step S2, performing mold flow analysis on the light guide strip product model to obtain model deformation data; Step S3, establishing a light guide strip optical model based on the model deformation data; Step S4, simulating the optical model of the light guide strip to obtain a light effect defect area; Step S5, obtaining a model compensation amount based on the light effect defect area, and generating an output model based on the model compensation amount.

[0029] First, by directly mapping the microstructure deformation data obtained from mold flow analysis to the optical model, the limitation of the separation of mold flow and light effect simulation data in traditional methods is broken, so that the compensation design can accurately associate geometric deformation with light intensity distribution; second, the light effect defect area is located based on optical simulation, replacing the traditional method of relying on manual experience to judge the defect location, avoiding the extension of production cycle caused by invalid compensation and reducing production costs.

[0030] Specifically, see Figure 1 Step S5 also includes detecting whether the output model meets the standard. If not, a light guide strip product model is established according to the output model, and then returning to step S2.

[0031] First, by optimizing the design through closed-loop feedback and iteratively updating the light guide strip product model, the geometric compensation amount is gradually approached to the theoretical optimal value, avoiding the inefficiency caused by repeated mold modifications in the traditional trial and error method, and improving the design accuracy and reliability. Second, by replacing the traditional manual adjustment of product parameters, the time spent on compensation parameter correction is greatly reduced.

[0032] Specifically, see Figure 2-Figure 7 , step S2 also includes: performing mold flow analysis on the light guide strip product model based on material parameters and process parameters.

[0033] For example, moldflow is used to perform mold flow analysis on the light guide strip product model.

[0034] Combining material and process parameters for simulation, the deformation trend in actual molding can be accurately predicted, reducing the prediction deviation caused by lack of experience. At the same time, defects caused by process parameter mismatch can be predicted and avoided in the mold flow stage, reducing mold trial costs.

[0035] Specifically, the mold flow analysis of the light guide strip product model based on material parameters and process parameters includes selecting the mold surface temperature and the melt temperature to determine the molding data of the light guide strip product model.

[0036] For example, the mold surface temperature is set to 80°C and the melt temperature is set to 290°C.

[0037] Combining the interaction between melt temperature and mold surface temperature, the phase change process of the material from molten state to solid state is accurately simulated, which greatly reduces the prediction error of shrinkage deformation.

[0038] Specifically, the mold flow analysis of the light guide strip product model based on material parameters and process parameters also includes selecting injection time, holding time and holding pressure to determine the melt filling data.

[0039] For example, the holding pressure is 80MPa, the injection time is 2.5S, and the holding time is 6S.

[0040] First, by optimizing the matching of injection time and holding pressure, the uniformity of melt flow front speed is improved to avoid short shots or cavitation defects caused by uneven filling. Second, by combining the coupling setting of holding time and holding pressure, the shrinkage of melt cooling is effectively compensated, so that the volume shrinkage rate of light guide strips is effectively improved compared with traditional methods. Third, through multi-parameter collaborative analysis, the injection molding process is fully simulated, the molding quality is optimized, and the limitations of single parameter analysis are avoided.

[0041] Specifically, the material parameters also include material PVT curves and material thermal performance parameters, which are used to perform mold flow analysis on the light guide strip product model.

[0042] For example, the light guide strip in this application is made of Covestro PC HL-3003 material.

[0043] First, based on the PVT curve, the volume change of the material during the melting-cooling phase change process is quantified to reduce the shrinkage prediction error; second, the thermal conductivity of the material and the mold cooling rate are combined to predict the impact of the local temperature gradient on microstructure forming; third, for different materials, the mold flow analysis parameters are dynamically adjusted to reduce the adaptation error of the shrinkage compensation amount of the two materials under the same process and reduce the over-compensation rate.

[0044] For example, see Figure 3-Figure 5 According to the deformation in the three directions of XYZ generated in the mold flow analysis, the light guide strip product model is compensated and adjusted. Figure 6 This is an example of the deformation predicted after mold flow analysis of the light guide strip mentioned in this implementation. Figure 7 This is an example of compensating adjustments to the light guide strip product model.

[0045] Specifically, step S2 also includes: establishing an optical model of the light guide strip according to the refractive index and the surface scattering coefficient.

[0046] For example, a refractive index of 1.586 and a surface scattering coefficient of 0.0015 mm are selected.

[0047] For example, ANSY Speos is used to perform optical simulation on the optical model of the light guide strip.

[0048] First, the light path deviation of the deformed light guide strip is quantified by the refractive index, and the surface microstructure defects are evaluated in combination with the scattering coefficient to reduce the prediction error of light intensity uniformity. Second, based on optical parameter mapping, the recognition accuracy of light effect defect areas is improved, the area of ​​the compensation area is reduced, and the waste of resources caused by invalid compensation is avoided. Third, the impact of deformation on light efficiency is quantified through optical parameter modeling, replacing the traditional compensation method that only relies on geometric deformation, thereby improving the targetedness of light effect repair.

[0049] Specifically, see Figure 1 , Figure 8 and Fig. 9 In step S3, the light guide strip optical model is preprocessed, and the preprocessing includes setting target optical parameters of the light guide strip optical model.

[0050] Clarify the lighting effect design goals to provide a benchmark for compensation calculation and avoid the compensation direction deviating from actual needs.

[0051] Specifically, see Figure 8 and Fig. 9Step S5 further includes: obtaining the light guide parameters after deformation according to the model deformation data, and obtaining the model compensation amount according to the light guide parameters after deformation, and the model compensation amount is: = +k·( - ); in, is the light guiding parameter after deformation, is the target optical parameter, is the compensation parameter, and k is the material-structure coefficient.

[0052] Firstly, the k-value is used to couple geometric deformation and optical performance to improve the efficiency of repairing light uniformity. Secondly, mathematical model fitting is used to improve the compensation accuracy for the deformation of the curved surface of the light guide and the nonlinear response of light intensity loss.

[0053] Specifically, see Fig. 9 The material-structure coefficient is selected by the luminous flux loss rate. The luminous flux loss rate calculation formula is: (initial design luminous flux - measured luminous flux) / initial design luminous flux × 100%, where the initial design luminous flux is the target luminous flux, and the measured luminous flux is obtained by measuring the output model.

[0054] First, based on the measured luminous flux loss rate, the production cost can be reduced and over-compensation can be reduced. Second, in view of the performance fluctuations of different batches of the same material, the luminous flux consistency of the light guide strip can be improved by controlling the k value. Third, based on the measured luminous flux, the compensation coefficient is dynamically optimized to solve the problem that the traditional fixed compensation coefficient cannot adapt to different materials and structures.

[0055] Although the present invention is disclosed as above, the present invention is not limited thereto. Any person skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the scope defined by the claims.

Claims

1. A deformation compensation design method for an automobile light guide strip, characterized in that: The deformation compensation design method comprises: Step S1, establishing a light guide strip product model; Step S2, performing mold flow analysis on the light guide strip product model to obtain model deformation data; Step S3, establishing a light guide strip optical model based on the model deformation data; Step S4, simulating the optical model of the light guide strip to obtain a light effect defect area; Step S5, obtaining a model compensation amount based on the light effect defect area, and generating an output model based on the model compensation amount.

2. The deformation compensation design method according to claim 1, characterized in that: The step S5 further includes: detecting whether the output model meets the standard, and if not, rebuilding the light guide strip product model according to the output model, and then returning to step S2.

3. The deformation compensation design method according to claim 1, characterized in that: The step S2 further includes: performing mold flow analysis on the light guide strip product model based on material parameters and process parameters.

4. The deformation compensation design method according to claim 3, characterized in that: The mold flow analysis of the light guide strip product model based on material parameters and process parameters includes selecting mold surface temperature and melt temperature to obtain molding data of the light guide strip product model.

5. The deformation compensation design method according to claim 4, characterized in that: The mold flow analysis of the light guide strip product model based on material parameters and process parameters also includes selecting injection time, holding time and holding pressure to determine melt filling data.

6. The deformation compensation design method according to claim 5, characterized in that: The material parameters include: material PVT curve and material thermal performance parameters, which are used to perform mold flow analysis on the light guide strip product model.

7. The deformation compensation design method according to claim 1, characterized in that: The step S2 also includes: establishing an optical model of the light guide strip according to the refractive index and the surface scattering coefficient.

8. The deformation compensation design method according to claim 1, characterized in that: The step S3 further includes: preprocessing the optical model of the light guide bar, and the preprocessing includes: setting target optical parameters of the optical model of the light guide bar.

9. The deformation compensation design method according to claim 8, characterized in that: The step S5 further includes: obtaining the light guide parameters after deformation according to the model deformation data, and obtaining the model compensation amount according to the light guide parameters after deformation, wherein the model compensation amount is: = +k·( - )； in, is the light guiding parameter after deformation, is the target optical parameter, is the compensation parameter, and k is the material-structure coefficient.

10. The deformation compensation design method according to claim 9, characterized in that: The material-structure coefficient is selected by the luminous flux loss rate, and the luminous flux loss rate = (initial design luminous flux - measured luminous flux) / initial design luminous flux × 100%, the initial design luminous flux is the target luminous flux of the automotive light guide strip, and the measured luminous flux is obtained by measuring the output model.

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