Multi-Lens ADB Headlamp Assembly with Nested Holder
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Solution Overview
Problem
The complexity of high-resolution adaptive driving beam (ADB) headlamps requires an accurate assembly structure for multiple lenses to maintain a precise distance from the light source, which is challenging due to the increased number of lenses needed for sharp contrast and reduced beam angles, leading to potential shape distortion and assembly errors.
Innovation Solution
A lens assembly structure comprising a lens unit, a cam unit, a first barrel unit, and a second barrel unit, with specific through holes, fixing holes, and moving holes, allows for precise positioning and adjustment of lenses along the optical axis, ensuring correct alignment and maintaining an appropriate distance from the light source, utilizing a cylindrical shape and symmetrical couplings to achieve high-resolution ADB functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the number of segments is increased to reduce beam angle and improve sharpness, then the beam contrast ratio is improved, but the number of lenses required increases leading to assembly complexity
Solution Approach 1:
Multiple lenses are nested within a single integrated lens holder that incorporates positioning features and fixing mechanisms. The lens holder acts as a container that accommodates multiple lenses in a compact arrangement, with each lens positioned at a predetermined location relative to the light source, thereby reducing assembly complexity while maintaining the required number of lenses for sharp beam contrast
Solution Approach 2:
The lens holder is designed with pre-formed positioning protrusions and fixing holes that are manufactured in advance. These features enable the lenses to be positioned at exact predetermined distances from the light source during assembly, eliminating the need for complex adjustment procedures and ensuring accurate positioning without increasing assembly complexity
2Manufacturing precision
If more lenses are used to achieve higher resolution, then the sharpness is improved, but the assembly positioning accuracy becomes more difficult to maintain
Solution Approach 1:
The lens holder incorporates localized positioning features including protrusions that fit into corresponding recesses and fixing holes positioned at specific locations. Each lens has a predetermined position defined by these local structural features, ensuring that every lens is accurately positioned relative to the light source and other lenses, thereby maintaining high positioning accuracy across the entire multi-lens assembly
Solution Approach 2:
The positioning protrusions and fixing holes are pre-manufactured with precise dimensions and locations. This preliminary preparation of positioning features ensures that when lenses are assembled into the holder, they automatically achieve the correct positioning without requiring complex measurement or adjustment procedures during the assembly process
3Illumination intensity
If multiple lenses are assembled to reduce beam angle, then the contrast ratio is improved, but the assembly error increases
Solution Approach 1:
Multiple lenses are nested within a single lens holder that provides a unified structural framework. This nesting approach ensures that all lenses are positioned relative to a common reference frame (the lens holder itself), which minimizes cumulative assembly errors that would occur if lenses were positioned independently relative to each other or to the light source separately
Solution Approach 2:
The lens holder is pre-manufactured with fixing holes and positioning features at exact predetermined locations. These features are designed to receive and secure lenses at specific positions, thereby preventing assembly errors before the assembly process begins and ensuring consistent positioning accuracy across production batches
Data Source
AI summary
Provided is a lens assembly applied to a head lamp, and the lens assembly may fix each of a plurality of lenses in an appropriate position to maintain an appropriate distance between the light source and the lens, thereby acquiring a resolution required by a high-resolution adaptive driving beam (ADB) lamp.