A method and system for simulating sunlight focusing of a vehicle lamp lens based on FLOEFD

Abstract

The application relates to a FLOEFD-based sunlight ray focusing simulation method and system for a vehicle lamp lens, which comprises the following steps: step S1, model processing, retaining parts with potential sunlight focusing risks; step S2, mesh division, discretely processing the retained part models; step S3, parameterized traversal, parameterizing the elevation and azimuth angles of the sunlight incidence, automatically queuing the irradiance of all design points and collecting; step S4, two-dimensional matrix generation, generating an irradiance two-dimensional matrix according to the irradiance of each design point arranged according to the elevation and azimuth angles; step S5, risk positioning, dividing a plurality of sub-zones according to the irradiance distribution in the irradiance two-dimensional matrix, and determining the angle combination with the maximum irradiance value in the sub-zones as the risk angle; and step S6, heat flow coupling analysis, judging whether there is a burning risk according to the comparison result of the temperature distribution of the temperature value cloud map and the reference limit temperature of the risk part; the scheme adopts the above method, and the efficiency is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of vehicle lighting simulation technology, and in particular to a method and system for simulating the focusing of sunlight through a vehicle lighting lens based on FLOEFD. Background Technology

[0002] Modern car headlights are generally equipped with lens-type lighting modules. The widespread use of LED and laser light sources has driven the lightweighting and diversification of headlight designs. However, lenses inherently have the defect of focusing sunlight. When vehicles are parked on slopes or in sunny conditions, sunlight is refracted and reflected by the lenses, forming high-energy sunspots on internal components such as black covers and plastic brackets. Dark plastic parts have a high heat absorption coefficient, and localized high temperatures can easily cause discoloration, melting, and failure of parts, thus affecting the appearance, function, and safety of the headlights.

[0003] To proactively mitigate the risk of solar ablation, the industry relies on SPEOS for optical simulation and screening. For example, a Chinese invention patent with publication number CN121580593A discloses a method for finding the focusing direction of sunlight based on CATIA, which includes: constructing a 3D model of a lens and 3D models of the parts arranged around the lens; reading the solar source model, where the solar source plane in the solar source model is incident on the lens at different azimuth angles, and selecting the current incident azimuth angle of the sunlight; collecting the maximum irradiance on the parts around the lens at the current incident azimuth, and calculating the ratio of this maximum irradiance to the reference irradiance when the sunlight is directly overhead in the non-focused state; when the ratio is greater than or equal to a set ratio threshold, it is determined that the sunlight at the current azimuth angle has a focusing risk; changing the current incident azimuth angle of the sunlight until all azimuth angles in the solar source plane of the solar source are traversed, and the azimuth angle with the largest ratio among those with focusing risk is identified as the solar focusing direction of the lens. The solution involves optical engineers using optical analysis and software to find the angle at which the sun is focused. Each angle of incidence needs to be modeled and calculated independently, and this repetitive modeling leads to a lengthy development cycle. Subsequently, thermal engineers need to use additional software to analyze the temperature field of the entire product at the specified focusing angle to determine the temperature of the components at the focusing position and thus determine whether it has failed. Otherwise, there is a lack of quantitative evaluation standards for irradiance, and only a qualitative assessment of the risk can be made. It is impossible to accurately locate the highest energy focusing position, making it difficult to provide accurate data support for structural optimization.

[0004] Furthermore, a Chinese invention patent with publication number CN116975943B discloses a method for simulating and analyzing solar light focusing in a vehicle headlight lens. The method includes: step S1, designing parameters; step S2, establishing a model; step S3, data preprocessing; step S4, dividing the data into cells; step S5, simulation calculation; and step S6, where the central control processor calculates simulation parameter values ​​based on the simulation results and preliminarily determines the burn risk level of the plastic component. When the central control processor determines that the plastic component is in a burn state, it adjusts the distance between the plastic component and the center of the lens to a corresponding value or adjusts the parameters of the curve equation of the vehicle headlight lens surface to a corresponding value based on the calculated simulation parameter values. This method obtains a single comprehensive value C from a single simulation, indirectly inferring the risk level by comparing the C value with a threshold, using a single point or a limited preset angle, followed by trial-and-error adjustments, and involves numerous manual repetitions. Summary of the Invention

[0005] To address the aforementioned issues, the present invention aims to provide a method and system for simulating solar beam focusing in automotive headlight lenses based on FLOEFD, which can effectively improve the analysis efficiency, the comprehensiveness of risk screening, the accuracy and reliability of judgment, and the ease of operation of simulation analysis of solar beam focusing in automotive headlight lenses.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A method for simulating sunlight focusing in automotive headlight lenses based on FLOEFD, characterized by comprising:

[0008] Step S1: Model processing. Obtain the 3D model of the headlights in FLOEFD, retain parts with potential risks of sunlight focusing, and simplify structural features without risks.

[0009] Step S2: Mesh generation. Discretize the retained part model, set up a non-fluid computational domain, generate a mesh on the part to capture the path of sunlight, and test the iteration time for temperature stability under non-fluid simulation conditions.

[0010] Step S3: Parametric traversal. The elevation and azimuth angles of the solar incidence are parameterized, and the range and interval angles are defined. Several solar incidence angle design points are generated by arranging and combining them. The irradiance of all design points is automatically calculated and collected.

[0011] Step S4: Two-dimensional matrix generation. The script automatically reads the collected irradiance information, arranges the irradiance corresponding to each design point according to the elevation angle and azimuth angle to generate an irradiance two-dimensional matrix, and performs continuity verification and correction on the two-dimensional matrix.

[0012] Step S5: Risk positioning. Divide the irradiance distribution in the two-dimensional irradiance matrix into several partitions, select several partitions with relatively large irradiance, and determine the angle combination with the largest irradiance value in these partitions as the risk angle.

[0013] Step S6: Thermal-fluid coupling analysis. Based on the risk perspective, the entire headlight model is rebuilt. Air medium is introduced into the computational domain to perform coupled calculations of the temperature field and flow field to obtain the temperature value cloud map of each risky component. Based on the comparison between the temperature distribution of the temperature value cloud map and the reference limit temperature of the risky component, it is determined whether there is a risk of burning.

[0014] Preferably, in step S1, the calculation model adopts the Monte Carlo simulation method, and the number of light beams is set to no less than 10,000,000 per ellipsoid.

[0015] Preferably, in step S1, the interference between parts in the model is removed by Boolean cutoff of parts that would deform in actual assembly; the coplanar parts between parts are parts that have no potential risk of movement, ensuring a spacing of 0.02mm.

[0016] Preferably, in step S2, the grid is divided by setting the grid size of the lens to less than 1 mm, the grid size of the transparent mask to 2 mm, and the grid size of the potentially hazardous parts to 2.5 mm.

[0017] Preferably, in step S3, the elevation and azimuth angles of sunlight entering each risk component are parameterized, defining the elevation angle as 0°~180° and the azimuth angle as 0°~180°, with each elevation and azimuth angle in a 5° interval; orthogonal experiments are used to establish experimental objects for the azimuth and elevation angles, with each design point corresponding to an angle combination of azimuth and elevation angles, and FLOEFD automatically queues and calculates the irradiance of all design points and collects it into a table.

[0018] As a preferred option, the elevation angle and azimuth angle are arranged in descending order of their respective values.

[0019] Preferably, in step S4, the two-dimensional irradiance matrix has the elevation angle as the vertical axis and the azimuth angle as the horizontal axis. Each cell in the matrix corresponds to an angle combination of elevation angle and azimuth angle, and the value of the cell is the irradiance value of the surface of the risky part under that angle combination.

[0020] Preferably, in step S4, when performing continuity verification on the two-dimensional irradiance matrix, if there are singular values ​​that do not meet the continuity requirements, the singular values ​​are corrected and re-verified until the two-dimensional irradiance matrix meets the continuity requirements. Among them, singular values ​​are those in the two-dimensional irradiance matrix where the irradiance value does not change continuously with its adjacent values ​​above, below, left, and right. The singular value optimization method is to take the average value of the irradiance values ​​above, below, left, and right of the singular value and replace it with that value.

[0021] Preferably, in step S6, before obtaining the temperature value cloud map, the grid corresponding to the location of the risky part at each partition angle is refined, with a grid size of 0.5 mm.

[0022] A solar beam focusing simulation system for automotive headlight lenses based on FLOEFD, characterized in that: solar beam focusing simulation analysis is performed using any one of the methods described above.

[0023] The present invention adopts the above technical solution and has the following technical effects:

[0024] The above-mentioned scheme generates several design points for solar incidence angles by parametrically arranging and combining the solar elevation and azimuth angles. It then uses FLOEFD to systematically and automatically traverse all possible solar incidence angles, avoiding the shortcomings of traditional methods that miss key risk points due to simulations only for a limited number of preset angles. At the same time, this invention sets up a non-fluid computational domain and does not consider air participation in the calculation during the light screening stage, which greatly reduces the number of grids required for a single calculation and can significantly reduce the software's analysis time. After the risk angles are locked through the irradiance two-dimensional matrix, the air medium is then introduced for targeted fine thermal-fluid coupling analysis. This step-by-step strategy of "light screening first, then thermal calculation" saves computational resources to the maximum extent while ensuring analysis accuracy. Building upon this foundation, the visualization tool in this invention is developed using the VBA platform of Excel. It can automatically read irradiance data from all angular operating conditions and generate a two-dimensional irradiance matrix with elevation angle as the vertical axis and azimuth angle as the horizontal axis. This matrix visually presents the energy distribution patterns hidden in a large amount of raw data through a heatmap. Based on the irradiance distribution in the matrix, it automatically divides risk zones and accurately locates the angle combination with the highest irradiance value in each zone. This solves the technical problem of traditional methods, which cannot accurately locate the highest energy focusing azimuth due to the lack of structured processing of massive amounts of data. This provides accurate data support for subsequent structural optimization and significantly improves efficiency. Furthermore, this invention performs coupled calculations of the flow field and temperature field for the locked risk angles, directly obtaining the specific temperature distribution of the risky parts. By directly comparing it with the material reference limit temperature, it provides a clear failure judgment conclusion, realizing a leap from the traditional method of indirectly inferring the risk level through abstract simulation parameter values ​​to directly determining whether a part has failed. Furthermore, the core simulation calculations and analyses of all steps in this invention are completed within the single FLOEFD software platform. The irradiance two-dimensional matrix visualization tool is an independent auxiliary post-processing tool. Thermal engineers can complete the entire process from optical screening to thermal analysis without switching between different software and transferring data. This avoids the loss of accuracy and efficiency in cross-software data transfer, significantly reduces the amount of repetitive manual operations and the probability of errors, and significantly improves the overall efficiency and reliability of the simulation analysis of solar focusing on vehicle headlight lenses. Attached Figure Description

[0025] Figure 1 This is a schematic diagram illustrating the steps of a method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD.

[0026] Figure 2 A simplified cross-sectional diagram of the headlight model.

[0027] Figure 3 This is a schematic diagram of the azimuth angle of sunlight incidence.

[0028] Figure 4 This is a schematic diagram showing the angle of elevation of sunlight.

[0029] Figure 5 A schematic diagram illustrating how visualization tools obtain azimuth, elevation, and irradiance information.

[0030] Figure 6 This is a schematic diagram of a two-dimensional irradiance matrix.

[0031] Figure 7 This is a cloud map showing the first temperature value of the high and low beam bezels.

[0032] Figure 8 This is a cloud map showing the second temperature value of the high and low beam bezels.

[0033] Figure 9 This is a schematic diagram comparing the focusing temperature of the high and low beam bezels with the reference limit temperature of the parts under the second temperature value cloud map. Detailed Implementation

[0034] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0035] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0036] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more, unless explicitly defined otherwise.

[0037] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0038] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0039] like Figure 1 The method shown is a simulation method for focusing sunlight through a vehicle headlight lens based on FLOEFD, comprising:

[0040] Step S1: Model processing. Obtain the 3D model of the vehicle headlights in FLOEFD, retaining parts with potential solar focusing risks, and simplifying non-risk structural features, such as... Figure 2 As shown, the parts that generally pose a potential risk are those surrounding the ellipsoidal lens 1, such as the ellipsoidal support 2, the ellipsoidal decorative ring 3, the decorative ring 4, the black mask 5, and the transparent mask 6; Figure 2 As shown, simplifying the structure without affecting the results can significantly reduce the software's analysis time. The model processing mainly focuses on interference and coplanar parts between components. Interference is addressed by Boolean cutoff of parts that would deform in actual assembly. During mesh generation, distorted meshes are generated in overlapping areas, leading to FLOEFD solution failure or result distortion. Therefore, Boolean cutoff is necessary to remove the interference from parts that would deform in actual assembly. Coplanar parts are those where moving them poses no potential risk, maintaining a spacing of 0.02mm. If two coplanar surfaces completely overlap, Boolean operations may fail. However, coplanarity itself does not represent positional conflict, but rather surface fit. Therefore, only parts without potential risk need to be moved, translated 0.02mm along the surface normal direction to create a tiny gap. This gap is small enough not to affect the accuracy of optical simulation, but sufficient for the software to recognize them as two independent surfaces, avoiding abnormal mesh generation.

[0041] Model simplification is essential, as the structural design model includes all process and assembly features. Without simplification, the software may be unable to perform calculations due to the structural complexity.

[0042] Step S2: Mesh generation. Discretize the retained part model, set up a non-fluid computational domain, divide the mesh on the part to capture the path of sunlight, and test the iteration time for temperature stability under non-fluid simulation conditions.

[0043] In this invention, a 3D car headlight model (lens, bracket, mask, etc.) needs to be divided into tens of thousands of tiny three-dimensional grids (small squares). The location of the light and the temperature are determined by calculating the data of each small square.

[0044] The absorption factor of transparent parts and the surface emissivity of opaque parts need to be obtained based on actual experimental tests.

[0045] In this invention, the influence of air on the path of sunlight is not affected by whether air is considered or not within the computational domain.

[0046] In this invention, air is not considered before locating the risk coordinates of the risky component to save analysis time. However, air in the computational domain must be considered after locating the risk coordinates because air participates in surface convection and heat dissipation at the risk point. That is, when performing focused analysis by tracking sunlight, air should not be considered in the calculation. An air computational domain introduces a large number of fluid meshes, geometrically increasing the calculation time for each solar angle.

[0047] In this invention, the computational domain is a cubic region that includes the model outline.

[0048] The meshing prioritizes lenses (less than 1mm) to capture fine features and spherical curvature. Next, transparent masks are meshed at 2mm. Finally, potentially hazardous components are meshed at 2.5mm. The mesh size aims to capture the path of sunlight, as focused light energy is highly concentrated. If the mesh is too coarse, the light spot will leak between two small squares, resulting in calculated energy being nonexistent. This ensures that regardless of the angle from which sunlight enters, the high-energy focused spot will hit at least several grid cells. This allows the software to accurately capture the highest energy areas, providing accurate data for subsequent matrix generation. Simultaneously, it controls the overall mesh size while maintaining accuracy in capturing the light path. This differentiated meshing strategy allows for the rational allocation of computational resources. Densification in critical optical areas improves ray tracing accuracy, while a relatively coarser mesh is used in non-critical areas to reduce computational load, maximizing computational efficiency while maintaining simulation accuracy.

[0049] The analytical model employs Monte Carlo simulation to accurately capture the focusing of light rays, ensuring that each ellipsoid contains at least 10,000,000 light rays. Setting the number of light rays to at least 10,000,000 guarantees the statistical convergence of the ray tracing results and the stability of the irradiance data. This ensures that even in high-energy-density focusing regions, the statistical error of irradiance can be controlled within an acceptable range, guaranteeing that the irradiance distribution in the two-dimensional matrix accurately reflects the actual focusing energy distribution.

[0050] Step S3, parameterized automatic traversal, such as Figure 3 The figure shows the azimuth angle of the incoming sunlight, as shown. Figure 4 The diagram shows the elevation angle of sunlight incidence. The elevation (height angle) and azimuth angle of sunlight incidence on each risk component are parameterized. Orthogonal experiments are used to establish experimental objects for the azimuth and elevation angles. The azimuth and elevation angles are automatically combined to generate several design points for solar incidence angles. Each design point corresponds to a combination of azimuth and elevation angles. The elevation angle is defined as 0°~180° and the azimuth angle as 0°~180°, with each angle interval being 5°. This angle range covers all possible sunlight incidence directions for the headlights in their headlight mounting posture, resulting in 1369 angle combinations. This ensures a systematic and comprehensive screening of all possible operating conditions. The 5° angle interval represents the optimal balance between accuracy in covering risk angles and computation time in engineering practice, keeping the computational load within acceptable engineering limits while ensuring the capture of peak risk angle regions. FLOEFD automatically queues and traverses the irradiance of all design points and collects it into a table, eliminating the need for manual modeling and calculation submission, significantly improving analysis efficiency.

[0051] In this invention, each monitored component generates a numerical value and saves it in an Excel file, and the irradiance of all monitored components is also saved in an Excel file. It should be noted that during the iteration, collecting an angle combination will calculate the irradiance under that angle combination, but the result cannot determine the distribution relationship and trend of solar angle and irradiance.

[0052] In this invention, the angles of all risky components are parameterized together, and the angles are different for different components.

[0053] The elevation and azimuth angles are arranged in descending order. This rule establishes a deterministic design point traversal sequence for FLOEFD automatic queuing calculation, ensuring the uniqueness and consistency of data mapping relationships throughout the entire automated chain from angle arrangement, automatic calculation, and data acquisition in step S3 to the generation of the two-dimensional matrix in step S4, and avoiding data misalignment caused by uncertain traversal order.

[0054] Step S4: Generation of a two-dimensional matrix, as follows Figure 5 As shown, the script automatically reads the irradiance information collected from the Excel file. In this file, the data is presented in a flat list format; the human eye cannot directly judge which angular area has high irradiance or which area is safe by looking at these numbers. Figure 6 As shown, the irradiance corresponding to each design point is arranged according to elevation and azimuth angles to generate a two-dimensional irradiance matrix. The irradiance matrix has elevation angle as the vertical axis and azimuth angle as the horizontal axis. Each cell in the matrix corresponds to an angle combination of elevation and azimuth angles, and the value of the cell is the irradiance value of the surface of the risky part under that angle combination. In this way, the data restores the two-dimensional spatial structure, and the position of each cell (which row and column) represents the position of that angle combination in angle space.

[0055] In this invention, the irradiance must meet the continuity requirement. If there are outliers, their effects need to be eliminated after assessment. That is, when performing continuity verification on the two-dimensional irradiance matrix, if there are outliers that do not meet the continuity requirement, the outliers are corrected and the verification is repeated until the two-dimensional irradiance matrix meets the continuity requirement. In other words, if a certain value in the generated irradiance matrix does not change continuously with the values ​​above, below, left, and right, it is manually adjusted and the average value of the above, below, left, and right is used to replace that value.

[0056] In this invention, the irradiance matrix serves as the detection risk indicator for the solar incidence direction. Risk assessment is not based solely on irradiance. Instead, a qualitative analysis is conducted to determine which angular ranges are close to and far from the focal point. This allows for further analysis of the temperature distribution near the focal angle.

[0057] In this invention, the irradiance two-dimensional matrix visualization tool is a script tool developed based on the EXCEL VBA platform, such as... Figure 5 As shown, on the left, click the first step to read the Excel file generated by the monitoring, which automatically reads the massive amount of irradiance data calculated by FLOEFD. The second step is to generate the irradiance matrix for each part, which will give you the results. Figure 6 The irradiance matrix displayed for each part, which is a color two-dimensional matrix heat map, allows engineers to see at a glance which angle poses the highest risk.

[0058] Step S5: Risk identification. Analyze the two-dimensional irradiance matrix of each risky component, and partition the irradiance distribution in the matrix. Each partition represents the variation of irradiance within a continuous range, such as... Figure 6 It is divided into Zone I and Zone II.

[0059] like Figure 6As shown, several zones with relatively high irradiance are intuitively selected, such as Zone I with azimuth [-70°~-60°] and elevation [0°~10°]. The angular coordinates of the risky parts being irradiated are not much different. The angle with the highest irradiance, such as ~-65° in Zone I, is selected as the potential risk angle. Based on this, the risk angles of different zones are obtained for further temperature analysis.

[0060] Step S6: Thermal-fluid coupling analysis. Based on the risk perspective, the entire headlight model is rebuilt, considering airflow heat transfer. Air is introduced into the computational domain to perform coupled calculations of the temperature and flow fields, obtaining temperature cloud maps for each risk component. In Step S5, based on the energy distribution of the irradiance two-dimensional matrix, several risk zones (e.g., Zone I, Zone II) are defined. Each zone corresponds to an angular range, representing a relatively concentrated area of ​​focused energy. Temperature analysis is performed on individual risk components for each zone.

[0061] Each partition yields a temperature cloud map of a part. The temperature cloud map is a color three-dimensional distribution map that uses color changes to represent the temperature of various points on or inside the part, and can intuitively display the actual temperature of the part under the focus of the sun.

[0062] like Figure 7 The image shown is a temperature cloud map of the high and low beam surrounds at an elevation angle of 0° and an azimuth angle of -65°.

[0063] like Figure 8 The image shown is a temperature cloud map of the high and low beam surrounds at an elevation angle of 50° and an azimuth angle of -35°.

[0064] In this invention, the location of the risky part at the risk angle within each partition is locally refined with a mesh size of 0.5 mm. This eliminates the influence of mesh size on temperature and yields accurate temperature results.

[0065] like Figure 9 As shown, the presence of a risk of burning is determined by comparing the temperature distribution in the temperature cloud map with the reference limit temperature of the hazardous component. If a risk is identified, relevant improvement suggestions are proposed, such as... Figure 8 As shown, the high and low beam bezels at an elevation angle of 50° and an azimuth angle of -35° are 166° considering airflow. From... Figure 9 It can be seen that using PC material for the high and low beam bezels is risky. It is recommended to use high-temperature resistant PBT+PET material instead, which can avoid the risk of burning.

[0066] This invention employs a scheme comprising six steps: model processing, mesh generation, parametric traversal, two-dimensional matrix generation, risk location, and thermal-fluid coupling analysis. Through the coordinated operation of these steps, a step-by-step solar focusing risk simulation analysis, from comprehensive light screening to precise thermal analysis, is achieved. Specifically, step S3 generates design points for all possible combinations of solar incidence angles through parametric traversal and automatically queues them for calculation, solving the problem of lengthy development cycles caused by manual modeling in traditional methods. Step S4 automatically generates a two-dimensional irradiance matrix through scripts and performs continuous verification and correction, solving the problems of lack of structured processing of massive irradiance data and the inability of the human eye to intuitively identify risk distribution patterns, significantly improving efficiency. Step S5 accurately locates the angle combination with the highest irradiance based on matrix partitioning as the risk angle, overcoming the shortcomings of traditional methods that can only qualitatively judge risks and cannot accurately locate the highest energy focusing direction. Step S6 performs thermal-fluid coupling analysis on the locked risk angles and determines the failure risk by directly comparing the temperature with the reference limit temperature, making risk assessment more intuitive and accurate. The core simulation calculations and analyses described above are completed within the FLOEFD single software platform. The irradiance two-dimensional matrix visualization tool is an independent auxiliary post-processing tool, eliminating the need to switch between different software and transfer data, thus significantly improving analysis efficiency.

[0067] In addition, the present invention also discloses a solar beam focusing simulation system for automotive headlight lenses based on FLOEFD, which uses the above-mentioned method to perform solar beam focusing simulation analysis.

[0068] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0069] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.

Claims

1. A method for simulating sunlight focusing in automotive headlight lenses based on FLOEFD, characterized in that: include: Step S1: Model processing. Obtain the 3D model of the headlights in FLOEFD, retain parts with potential risks of sunlight focusing, and simplify structural features without risks. Step S2: Mesh generation. Discretize the retained part model, set up a non-fluid computational domain, divide the mesh on the part to capture the path of sunlight, and test the iteration time for temperature stability under non-fluid simulation conditions. Step S3: Parametric traversal. The elevation and azimuth angles of the incident sunlight are parameterized, and the range and interval angles are defined. Several design points for the solar incident angle are generated by arranging and combining them. The irradiance of all design points is automatically calculated and collected. Step S4: Two-dimensional matrix generation. The script automatically reads the collected irradiance information, arranges the irradiance corresponding to each design point according to the elevation angle and azimuth angle to generate an irradiance two-dimensional matrix, and performs continuity verification and correction on the two-dimensional matrix. Step S5: Risk positioning. Divide the irradiance distribution in the two-dimensional irradiance matrix into several partitions, select several partitions with relatively large irradiance, and determine the angle combination with the largest irradiance value in these partitions as the risk angle. Step S6: Thermal-fluid coupling analysis. Based on the risk perspective, the entire headlight model is rebuilt. Air medium is introduced into the computational domain to perform coupled calculations of the temperature field and flow field to obtain the temperature value cloud map of each risky component. Based on the comparison between the temperature distribution of the temperature value cloud map and the reference limit temperature of the risky component, it is determined whether there is a risk of burning.

2. The method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD according to claim 1, characterized in that: In step S1, the calculation model uses the Monte Carlo simulation method, and the number of light beams is set to no less than 10,000,000 per ellipsoid.

3. The method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD according to claim 1, characterized in that: In step S1, the interference between parts in the model is removed by Boolean cutout of parts that would deform in actual assembly; the coplanar parts between parts are parts that can be moved without potential risk, ensuring a spacing of 0.02mm.

4. The method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD according to claim 1, characterized in that: In step S2, the mesh is divided by setting the mesh size of the lens to less than 1 mm, the mesh size of the transparent mask to 2 mm, and the mesh size of the potentially hazardous parts to 2.5 mm.

5. The method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD according to claim 1, characterized in that: In step S3, the elevation and azimuth angles of sunlight entering each risk component are parameterized, defining the elevation angle as 0°~180° and the azimuth angle as 0°~180°, with each elevation and azimuth angle in a 5° interval. An orthogonal experiment is used to establish experimental objects for the azimuth and elevation angles, with each design point corresponding to an angle combination of azimuth and elevation angles. FLOEFD automatically queues and calculates the irradiance of all design points and collects it into a table.

6. The method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD according to claim 5, characterized in that: The elevation angle and azimuth angle are arranged in descending order of their respective values.

7. The method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD according to claim 1, characterized in that: In step S4, the two-dimensional irradiance matrix is ​​plotted with elevation angle as the vertical axis and azimuth angle as the horizontal axis. Each cell in the matrix corresponds to an angle combination of elevation angle and azimuth angle, and the value of the cell is the irradiance value of the surface of the risky part under that angle combination.

8. The method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD according to claim 7, characterized in that: In step S4, when performing continuity verification on the two-dimensional irradiance matrix, if there are singular values ​​that do not meet the continuity requirements, the singular values ​​are corrected and re-verified until the two-dimensional irradiance matrix meets the continuity requirements. Among them, singular values ​​are those in the two-dimensional irradiance matrix where the irradiance value does not change discontinuously with its adjacent values ​​above, below, left, and right. The singular value optimization method is to take the average value of the irradiance values ​​above, below, left, and right of the singular value and replace it with that value.

9. The method for simulating sunlight focusing in a vehicle headlight lens based on FLOEFD according to claim 1, characterized in that: In step S6, before obtaining the temperature value cloud map, the grid corresponding to the location of the risky part at each partition angle is refined, with a grid size of 0.5 mm.

10. A solar beam focusing simulation system for automotive headlight lenses based on FLOEFD, characterized in that: The method described in any one of claims 1 to 9 is used to perform a simulation analysis of solar beam focusing.

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