LED Module Alignment for Vehicle Lighting
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Solution Overview
Problem
Existing methods for assembling LED lamps in vehicles, such as airplanes and trains, face challenges due to large positional tolerances in LEDs and optical systems, leading to inefficiencies in light intensity and imaging accuracy, making it difficult to achieve desired light distribution and brightness.
Innovation Solution
A method involving relative movement of the LED module and optical unit along the optical axis until the desired light intensity is detected, followed by fixation using a detector and curable adhesive, allowing for compensation of positional tolerances and automation of the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If LEDs and optical systems are assembled with conventional positioning methods, then assembly is simple and fast, but positional tolerances cause poor light intensity and imaging accuracy
Solution Approach 1:
The patent applies preliminary action by pre-positioning the LED module and optical system at a specific relative location before final fixation. The method involves moving the LED module and optical system to a predetermined relative position along the optical axis, then fixing them in place using adhesive or mechanical means. This pre-positioning ensures that even with manufacturing tolerances in LED and optical component positions, the final assembled light intensity and imaging accuracy meet requirements.
2Volume of moving object
If the optical system is made smaller to reduce lamp depth, then the overall size is reduced, but positional tolerances have greater impact on performance
Solution Approach 1:
The patent applies preliminary action by pre-positioning the LED module and optical system at a specific relative location before final fixation. The method involves moving the LED module and optical system to a predetermined relative position along the optical axis, then fixing them in place using adhesive or mechanical means. This pre-positioning ensures that even with manufacturing tolerances in LED and optical component positions, the final assembled light intensity and imaging accuracy meet requirements.
3Ease of manufacture
If LEDs with larger positional tolerances are used, then component selection is easier and cost is reduced, but assembly accuracy deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-positioning the LED module and optical system at a specific relative location before final fixation. The method involves moving the LED module and optical system to a predetermined relative position along the optical axis, then fixing them in place using adhesive or mechanical means. This pre-positioning ensures that even with manufacturing tolerances in LED and optical component positions, the final assembled light intensity and imaging accuracy meet requirements.
4Manufacturing precision
If manual adjustment of light intensity is used, then precision is achieved, but productivity is reduced
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated positioning and fixation system. The method uses a fixation device that can automatically move the LED module and optical system to the correct relative position and fix them in place. This automation eliminates the need for manual adjustment while maintaining precision, thereby significantly improving assembly productivity.
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 ensures precise alignment and fixation of LED lamps, reducing the reject rate and enabling efficient light intensity adjustment, resulting in improved light distribution and brightness while allowing for automated quality assurance and thermal monitoring.
Implementation Method 1
The LED module is controlled to emit electromagnetic radiation, which is used to illuminate a measuring surface by means of the optical unit
Implementation Method 2
The curing of the adhesive mass is expediently effected by UV radiation
Data Source
Figure 1~3
AI summary
The method for mounting an LED light, in particular a reading or seat light for a vehicle, such as an airplane or a coach, comprising an LED module and a reflective and/or refractive optical unit, comprises the following steps: - providing an LED module (12) comprising at least one LED (22), - providing a reflective and/or refractive optical unit (14) for illumination in a measurement plane by electromagnetic radiation from the LED module (12) and the optical unit, - arranging the optical unit (14) and the LED module (12) for subsequent fixing to one another, - controlling the LED module (12) to emit electromagnetic radiation for the purpose of illuminating the measurement plane, - detecting at least a part of the electromagnetic radiation from the LED module (12) incident on the measurement plane by a detector (18).- Moving the LED module (12) relative to the optical unit (14) and/or the optical unit (14) relative to the LED module (12) along the optical axis (16) until the detector (18) detects electromagnetic radiation from the LED module (12) with a predefinable intensity, and - fixing the optical unit (14) and the LED module (12) relative to each other in their current relative positions.