Aiming High Definition Pixel Light Modules via Projected Shapes
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Solution Overview
Problem
Conventional methods for aiming vehicle headlights face challenges due to manufacturing variations between light modules and color variations at the cutoff line, leading to imprecise determination of the cutoff line and hot spot center, affecting the final aim of the light module.
Innovation Solution
Aiming method using high definition pixel light sources, such as monolithic LED arrays or Digital Micromirror Devices, which project specific shapes onto a receiving area to determine the center and edges of the light source, allowing for precise adjustment of the light module's orientation by calculating positional and angular offsets based on projected patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional beam patterns with cutoff lines and hot spots are used for aiming, then the light module can provide illumination, but color variations at the cutoff line cause difficulty in determining the precise location of the cutoff line and hot spot center
Solution Approach 1:
The patent uses a projected shape (a simplified geometric representation) that copies the essential alignment information from the complex beam pattern without the distracting color variations. The projected shape created by the HD pixel light source serves as a clean, unambiguous surrogate for determining center position and orientation, eliminating the harmful color variation effect while preserving the useful alignment function.
Solution Approach 2:
The projected shape acts as an intermediary element between the light source and the aiming measurement process. Instead of directly measuring the problematic beam pattern with color variations, the system first creates an intermediate projected shape that encapsulates the alignment information in a measurable, unambiguous form.
2Measurement precision
If manual or software-based determination of hot spot center is used, then the aiming process can be completed, but the process is imprecise and negatively affects the final aim of the light module
Solution Approach 1:
Instead of attempting to locate the center of the diffuse hot spot through imprecise manual or software analysis, the patent creates a projected shape with a well-defined geometric center. This copied representation provides an unambiguous reference point that can be measured precisely, eliminating the time-consuming and imprecise hot spot center determination process.
Solution Approach 2:
The patent changes the parameter being measured from the diffuse intensity distribution of the hot spot to the precise geometric properties of the projected shape. This parameter transformation converts an imprecise measurement problem into a precise one, enabling accurate center determination.
3Ease of manufacture
If conventional light modules with manufacturing tolerances are used, then production is feasible, but variations between each light module require initial calibration to within aiming tolerances
Solution Approach 1:
The HD pixel light source performs self-alignment by projecting a shape whose geometric properties (center, orientation) directly reveal the light source's positional and angular offsets. The system uses its own projected output as the reference for determining its alignment, eliminating the need for external calibration procedures and making the manufacturing process more straightforward.
Solution Approach 2:
The aiming system uses the projected shape as feedback to determine the light module's orientation and position. By analyzing the position and orientation of the projected shape on the aiming target, the system automatically calculates the required adjustments, creating a closed-loop feedback mechanism that eliminates manual calibration.
4Measurement precision
If high definition pixel light sources projecting specific shapes are used, then the center and edges of the light source can be precisely determined, but the device complexity increases
Solution Approach 1:
The HD pixel light source serves multiple functions: it provides the primary illumination function and simultaneously acts as an alignment reference by projecting the reference shape. This multi-functionality eliminates the need for separate alignment devices, reducing overall system complexity despite the increased capability of the light source itself.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method eliminates the need to account for manufacturing variations, reduces aiming time, and improves the accuracy of light module alignment, thereby enhancing the precision and efficiency of the aiming process.
Implementation Method 1
projecting at least one projected shape from a high definition pixel light source onto a receiving area of an aimer
Data Source
AI summary
A method of aiming a light module for a vehicle, the method including projecting at least one projected shape from a high definition pixel light source onto a receiving area of an aimer; determining the center point or edges of the high definition pixel light source based on the at least one projected shape; and adjusting the orientation of the light module to align the high definition pixel light source in a desired orientation.