Optical Positioning of LEDs on Vehicle Headlamp PCBs
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Solution Overview
Problem
Conventional methods for positioning LEDs in vehicle headlights are inaccurate due to manufacturing tolerances, requiring manual adjustment of optical elements like reflectors and lenses, which increases production costs and effort, as the precision of fastening structures on printed circuit boards does not match the precision of conductor tracks and light sources.
Innovation Solution
The method uses alignment marks on the printed circuit board that interact mechanically with complementary positioning means in the vehicle headlight, allowing for precise mechanical positioning of electronic components, such as LEDs, relative to these marks, eliminating inaccuracies and the need for subsequent optical element adjustments by using optical detection with cameras and parallel illumination to enhance precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional referencing methods using position markers on the circuit board are used, then the positioning process is simple, but the positioning precision is insufficient due to manufacturing tolerances in mounting structures
Solution Approach 1:
The patent replaces the mechanical positioning reference system (using physical position markers on the circuit board) with an optical reference system. The optical reference body with its reference marks provides a more precise reference that is independent of the circuit board's mechanical manufacturing tolerances, thereby substituting a mechanical system with an optical one to achieve higher positioning precision.
Solution Approach 2:
The patent introduces an optical reference body as an intermediary element between the circuit board and the positioning system. This optical reference body carries reference marks that serve as a more accurate reference framework, mediating the positioning process and eliminating the need to rely directly on the imprecise mechanical features of the circuit board itself.
2Manufacturing precision
If manual adjustment of optical elements is performed to compensate for positioning inaccuracies, then the positioning precision can be improved, but the production time and cost increase
Solution Approach 1:
The patent applies preliminary action by establishing a precise optical reference system before the component mounting process. The optical reference body with accurately positioned reference marks is prepared in advance, allowing the positioning system to achieve high precision automatically without requiring subsequent manual adjustment of optical elements, thus maintaining production efficiency.
Solution Approach 2:
The patent replaces manual mechanical adjustment of optical elements with an automated optical positioning system. The camera-based detection system automatically determines component positions relative to the optical reference marks, eliminating the need for manual adjustment operations and thereby maintaining high productivity while achieving high precision.
3Manufacturing precision
If tight tolerances are maintained for LED positioning relative to optical components, then the light pattern precision is improved, but the manufacturing complexity and adjustment requirements increase
Solution Approach 1:
The patent replaces complex mechanical alignment procedures with an optical referencing system. The camera detects the positions of LEDs relative to the optical reference marks, and this positional information is used to automatically adjust placement parameters, thereby achieving tight tolerances for light pattern precision without requiring complex mechanical adjustment mechanisms or procedures.
Solution Approach 2:
The patent implements feedback by using the camera to detect the actual positions of LEDs relative to the optical reference marks, and then using this detected information to adjust the placement parameters for subsequent components. This closed-loop feedback system ensures tight tolerances are maintained for light pattern precision while automating the process and reducing assembly complexity.
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 approach enables fully automated and precise positioning of electronic components, reducing errors and the effort required for aligning optical components, thus improving the efficiency and cost-effectiveness of headlamp production by ensuring accurate placement of LEDs relative to other optical elements.
Implementation Method 1
the at least one position mark is optically detected
Implementation Method 2
illumination with parallel light
Data Source
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AI summary
The invention relates to a method for positioning at least one electronic component (3) on a circuit board (1) provided for installation in a vehicle headlamp, wherein the circuit board (1) comprises at least one position mark and the positioning of the at least one electronic component (3) is carried out relative to the at least one position mark on the circuit board (1), wherein the at least one position mark is detected optically and is used for the positioning, wherein the at least one position mark used is at least one alignment mark (5, 6, 7, 8, 8', 8'') of the circuit board (1) which, in the vehicle headlamp, when the circuit board (1) is installed, interacts mechanically with a positioning means (9, 15) of the vehicle headlamp that is complementary to the alignment mark (5, 6, 7, 8, 8', 8').