WO2017210959A1 - 一种自适应远近光一体led多模组前照灯 - Google Patents

一种自适应远近光一体led多模组前照灯 Download PDF

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Publication number
WO2017210959A1
WO2017210959A1 PCT/CN2016/089990 CN2016089990W WO2017210959A1 WO 2017210959 A1 WO2017210959 A1 WO 2017210959A1 CN 2016089990 W CN2016089990 W CN 2016089990W WO 2017210959 A1 WO2017210959 A1 WO 2017210959A1
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light source
led
light
led light
adaptive
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PCT/CN2016/089990
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English (en)
French (fr)
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陈焕杰
石智伟
徐德浓
秦德斌
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广东雷腾智能光电有限公司
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Priority to EP16876977.6A priority Critical patent/EP3285001A4/en
Priority to US15/532,508 priority patent/US10137824B2/en
Publication of WO2017210959A1 publication Critical patent/WO2017210959A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/25—Projection lenses
    • F21S41/255—Lenses with a front view of circular or truncated circular outline
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q1/00—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor
    • B60Q1/02—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor the devices being primarily intended to illuminate the way ahead or to illuminate other areas of way or environments
    • B60Q1/04—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor the devices being primarily intended to illuminate the way ahead or to illuminate other areas of way or environments the devices being headlights
    • B60Q1/14—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor the devices being primarily intended to illuminate the way ahead or to illuminate other areas of way or environments the devices being headlights having dimming means
    • B60Q1/1415—Dimming circuits
    • B60Q1/1423—Automatic dimming circuits, i.e. switching between high beam and low beam due to change of ambient light or light level in road traffic
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/147—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q1/00—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor
    • B60Q1/0029—Spatial arrangement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q1/00—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor
    • B60Q1/0029—Spatial arrangement
    • B60Q1/0035—Spatial arrangement relative to the vehicle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q1/00—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor
    • B60Q1/0029—Spatial arrangement
    • B60Q1/0041—Spatial arrangement of several lamps in relation to each other
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/143—Light emitting diodes [LED] the main emission direction of the LED being parallel to the optical axis of the illuminating device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • F21S41/32—Optical layout thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/60—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/60—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution
    • F21S41/65—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution by acting on light sources
    • F21S41/663—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution by acting on light sources by switching light sources
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q2300/00—Indexing codes for automatically adjustable headlamps or automatically dimmable headlamps
    • B60Q2300/05—Special features for controlling or switching of the light beam
    • B60Q2300/054—Variable non-standard intensity, i.e. emission of various beam intensities different from standard intensities, e.g. continuous or stepped transitions of intensity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q2300/00—Indexing codes for automatically adjustable headlamps or automatically dimmable headlamps
    • B60Q2300/05—Special features for controlling or switching of the light beam
    • B60Q2300/056—Special anti-blinding beams, e.g. a standard beam is chopped or moved in order not to blind
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q2300/00—Indexing codes for automatically adjustable headlamps or automatically dimmable headlamps
    • B60Q2300/40—Indexing codes relating to other road users or special conditions
    • B60Q2300/42—Indexing codes relating to other road users or special conditions oncoming vehicle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/147—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device
    • F21S41/148—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device the main emission direction of the LED being perpendicular to the optical axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/151—Light emitting diodes [LED] arranged in one or more lines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/25—Projection lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2102/00—Exterior vehicle lighting devices for illuminating purposes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2102/00—Exterior vehicle lighting devices for illuminating purposes
    • F21W2102/10—Arrangement or contour of the emitted light
    • F21W2102/17—Arrangement or contour of the emitted light for regions other than high beam or low beam
    • F21W2102/19—Arrangement or contour of the emitted light for regions other than high beam or low beam for curves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2102/00—Exterior vehicle lighting devices for illuminating purposes
    • F21W2102/30—Fog lights

Definitions

  • the invention relates to the field of LEDs, in particular to an adaptive far and near light integrated LED multi-module headlight.
  • Car headlights are an important part of the car's lighting system, providing active safety protection for the car.
  • High-power white LED Light Emitting Diode
  • LED light sources It is an inevitable trend in the development of automotive headlamp technology.
  • Traditional headlamps are affected by the 360-degree illumination of traditional light sources.
  • the utilization of light is low and glare is easy to occur.
  • Large and glare is serious, however, the use of LEDs can improve the light utilization of the light source and reduce glare, and can greatly reduce the volume of the headlights to enhance the aesthetics.
  • most of the LED headlamps are designed by separately designing the high beam and low beam, or by using multiple optical units to complement the light. . Therefore, the design proposes an integrated optical design scheme of the headlights, integrating the high beam and low beam functions into the same optical system to realize the design of the LED near and far light integrated headlights.
  • the integrated headlamp design better solves the integration problem, but there are still some shortcomings in the intelligentization of road lighting, and the adaptability to different road environments is insufficient. With the development of automotive intelligent technology, the intelligentization of automotive lighting systems will be the future development direction. Thanks to its fast response and easy control, LEDs are easier to implement intelligently than traditional light sources.
  • headlamps based on the adaptive system AFS (Adaptive Front-lighting System) in the conventional light source headlamp system it mainly adjusts the illumination direction of the lamp head up and down, left and right during driving, or through Different light types produced by different light intercepting devices, the above two methods mainly achieve adaptive lighting through mechanical means, and there are many deficiencies in function, and the degree of intelligence is not high.
  • AFS Adaptive Front-lighting System
  • this design proposes an adaptive light-type control system based on LED light source module array, automatic compensation light and color temperature control system to improve the intelligent degree of headlights and achieve different road environment illumination requirements.
  • the whole system realizes modular design, with simple structure and convenient control.
  • the technical problem to be solved by the present invention is to provide an adaptive far and near light integrated LED multi-module headlamp, which improves the integration and intelligence of the lamp, has a simple structure, small volume and low manufacturing cost.
  • an adaptive far and near light integrated LED multi-module headlight comprising a near and far optical follow-up adaptive light type control system, a compensation light system and a color temperature control system;
  • the far and near optical follow-up adaptive light type control system comprises an LED light source module array, and the LED light source module array comprises a plurality of LED light source modules, wherein the two or more LEDs are arranged in parallel with each other and the optical axis is parallel to the center of the vehicle body.
  • the light source module forms a straight light source, and comprises one or more LED light source modules disposed outside the straight light source and having an acute angle between the optical axis and the center of the vehicle body to form a steering light source, and between the optical axis of the LED light source module in the steering light source and the center of the vehicle body
  • the angle of the light increases from the inside to the outside; the straight light source is closer to the center of the vehicle than the steering light source; when the vehicle is running normally, the straight light source is illuminated; when the vehicle is at night, the one or more LED light source modules in the straight light source are turned off.
  • the LED light source module includes a first LED light source and a first curved surface that cooperates with the first LED light source a reflector, a second LED light source, a second curved reflector and a convex lens matched with the second LED light source, and the LED light source module is driven close when the first LED light source is separately illuminated Light type LED light source when the first and second LED light simultaneously, an LED light source module hit high beam type;
  • the compensation light system comprises a plurality of upper polarization auxiliary light-filling units located above the near-and-near optical follow-up adaptive light type control system and a plurality of lower polarization auxiliary light-filling units located under the near-and-near optical follow-up adaptive light type control system;
  • the upper polarization auxiliary light-filling unit comprises an upper polarized LED light source and an upper polarized light reflecting surface, wherein the upper polarized LED light source is located at the bottom of the upper polarized light reflecting surface, and the light emitted by the upper polarized LED light source is reflected by the upper polarizing reflective surface, so that the light distribution angle is distributed.
  • the lower polarization auxiliary fill unit includes a lower polarized LED light source and a lower polarized light reflecting surface, and a lower polarized LED light source Located at the top of the lower polarized light reflecting surface, the light emitted by the lower polarized LED light source is reflected by the lower polarized light reflecting surface, so that the distribution angle of the light exiting angle is 6-10 degrees from the ground plane to automatically compensate the vehicle during deceleration and downhill. Light area.
  • the invention adopts a plurality of independent LED light source modules as the headlights, and the vehicle lights up by controlling different LED light source modules when going straight or turning, thereby realizing the near and far light spots and the light type when turning straight when traveling straight.
  • Polarization compensation system The system is specifically designed to accelerate or decelerate vehicles, heavy loads, hill climbs and urban roads.
  • the first LED light source and the second LED light source each include an LED chip, a circuit board and a heat sink, the circuit board is mounted on the heat sink, the middle of the circuit board is hollowed out, and the corresponding line on the heat sink Forming a mounting plane on the board hollow, the LED chip is fixed on the mounting plane; the surface of the circuit board is provided with a pad, the LED chip is connected to the pad through a gold wire; the hollow portion of the circuit board is formed with the mounting plane a groove filled with fluorescent silica gel.
  • the manufacturing method of the first LED light source and the second LED light source includes the following steps:
  • the high-reflection organic glue is poured into the hollowed out along the injection hole of the circuit board, so that the surrounding area around the LED chip to the hollow area of the circuit board is completely covered, the amount of glue filling does not exceed the surface of the LED chip, and the glue is solidified by heating;
  • the LED chip of the invention is directly connected with the lamp radiator for heat dissipation, reduces the junction temperature of the LED chip with greatly reduced thermal resistance, and the volume of the LED can be made smaller, and the purpose of placing the plurality of LED light source modules of the invention can be achieved. .
  • the highly reflective silicone material effectively reduces unnecessary light loss and greatly increases the light energy in the directivity range.
  • the design method of the first curved reflector includes the following steps:
  • Dividing the solid angle of the LED light source setting the LED as the coordinate origin, ⁇ is the angle between the plane of the outgoing ray and the X-axis and the XOZ plane, ⁇ is the angle between the outgoing ray and the X-axis; Uniform discretization, dividing ⁇ into i parts, for each ⁇ , dividing ⁇ into j parts, to obtain an array of ⁇ (i) and ⁇ (i, j);
  • Dividing the receiving surface mesh According to the light distribution requirement, corresponding to the division of the solid angle of the light source, the rectangular coordinate of the receiving surface is also divided into i parts in the x direction, and for each x, the y direction is divided into j. And obtaining an array of x(i) and y(i,j) in one-to-one correspondence with the array of ⁇ (i) and ⁇ (i,j) in the solid angle of the light source in the rectangular coordinate system of the receiving surface;
  • the luminous flux in each small solid angle is:
  • each alpha angle corresponds to a length y(i, j+1)-y(i,j) and a width x(i+1)-x(i)
  • the rectangular area the total energy of each rectangular area is:
  • Etotal 1 E c ⁇ [x(i+1)-x(i)] ⁇ [y(i,j+1)-y(i,j)] (3)
  • E c represents the illuminance value. Since the illuminance values of the regions I, II, III and IV are different, the preset illuminance E and the illuminance control factor ⁇ are different for different regions:
  • k takes a one-to-one correspondence with the I, II, III, and IV regions, and the ⁇ (k) values are different, and need to be continuously adjusted in the calculation according to the simulation results to reach the standard Claim;
  • the height is y(i, j+1)-y(i, j), and the bottom side is x(i+1)-x(i),
  • the total energy of the area is:
  • the energy emitted by the LED source is equal to the receiving surface without considering the loss of energy.
  • the received energy is obtained by the law of conservation of energy:
  • the law of the point on the free surface can be obtained by the law of the law of deflection.
  • the tangential plane is used to obtain the tangential plane.
  • the coordinates of the upper and lower points of the curve are obtained by finding the intersection of the plane and the incident ray. .
  • the vector form of the law of catadiopism can be expressed as:
  • n is the refractive index, where n is 1, Is the incident ray unit vector, the outgoing ray unit vector, and the unit normal vector;
  • the independent far and near light integrated automobile headlight light-emitting unit of the invention adopts two independent LED light sources to cooperate with corresponding reflective curved surfaces to form a near-far light type without additional mechanical structure. Adjusting the visor, only through the two reflective surfaces and the iteration of the two light sources can form the far-near light type of the automotive headlamp required by the ECE regulations, the precise heat dissipation structure and the assembly structure of the novel reflective surface. Simple, reliable and compact, LED light efficiency is maximized, energy efficient, and can be applied to LED matrix light source design of large headlights of various models.
  • the design method of the second curved reflector includes the following steps:
  • Dividing the receiving surface grid the far illumination requires that the center should have a higher brightness and gradually weaken toward the surrounding, and the rectangular coordinates of the receiving surface are also divided into i in the x direction. For each x, Dividing the y direction into j parts, and obtaining an array of x(i) and y(i,j) in one-to-one correspondence with the ⁇ (i) and ⁇ (i,j) arrays in the solid angle of the light source in the rectangular coordinate system of the receiving surface;
  • Illumination control factor setting Since the high beam requires the center illumination to be high and gradually weakens to the surroundings, the illuminance control factor is set for the grid ring line. For different loop lines:
  • the luminous flux in each small solid angle is:
  • each alpha angle corresponds to a length y(i, j+1)-y(i,j) and a width x(i+1)-x(i)
  • the rectangular area the total energy of each rectangular area is:
  • Etotal 1 E c ⁇ [x(i+1)-x(i)] ⁇ [y(i,j+1)-y(i,j)] (3)
  • E c represents the illuminance value
  • the illuminance values of the regions I, II, III, and IV are different, wherein 0 ⁇ ⁇ (k) ⁇ 1, and the values of k and the regions I, II, III, and IV are one by one.
  • the ⁇ (k) values are different, and need to be continuously adjusted in the calculation according to the simulation results to meet the standard requirements;
  • the height is y(i, j+1)-y(i, j), and the bottom side is x(i+1)-x(i),
  • the total energy of the area is:
  • the energy emitted by the LED source is equal to the energy received on the receiving surface, which is obtained by the law of conservation of energy:
  • the normal vector of the point on the surface is obtained by using this normal vector, and the coordinates of the upper and lower points of the curve are obtained by finding the intersection of the tangent plane and the incident ray.
  • the vector form of the law of catadiopism can be expressed as:
  • n is the refractive index, where n is 1, Is the incident ray unit vector, the outgoing ray unit vector, and the unit normal vector;
  • the model of the free-form surface is established: the discrete coordinate points of the free-form surface reflector are iteratively calculated by the above-mentioned design method, and the discrete points are saved as text files and imported into the three-dimensional graphics software SolidWorks, and the fitting is performed. Become a smooth surface, get the solid model of the reflector, and import it into the optical simulation soft Lucidshape, set the material properties of the lens, the properties of the light source and the properties of the receiving surface, and trace the resulting model.
  • the LED light source module array has a total of seven LED light source modules, wherein three LED light source modules are straight light sources, and four LED light source modules are steering light sources.
  • the four LED light source modules of the steering light source are sequentially arranged from the inside to the outside at an angle of 13 to 17 degrees, 17 to 21 degrees, 28 to 32 degrees, and 40 to 44 degrees.
  • the color temperature control system includes a plurality of front fog light LED light sources, the front fog light LED light source including an LED having a color temperature of 2700K, an LED having a color temperature of 7000K, and a fog light reflecting cup.
  • the headlights also include a closed-loop adaptive follow-up control system, which includes a body sensor group, a body control MCU and a headlight AFS subsystem AU, a body sensor group and a body control MCU connection, body control
  • the MCU controls the far and near optical follow-up adaptive light type control system, the compensation light system and the color temperature control system through the headlight AFS subsystem AU;
  • the body sensor group includes a vehicle body speed sensor, a body tilt/corner sensor, and a vehicle body weight Load sensor, body condition vibration sensor, steering wheel angle sensor, rain sensor, smog/snow sensor and downtown environment sensor.
  • the invention adopts a plurality of independent LED light source modules as the headlights, and the vehicle lights up by controlling different LED light source modules when going straight or turning, thereby realizing the near and far light spots and the light type when turning straight when traveling straight.
  • the polarization compensation system is specifically designed for vehicles that are accelerating or decelerating, heavy loads, hill climbing and urban roads.
  • the independent far and near light integrated automobile headlight light-emitting unit of the invention adopts two independent LED light sources to cooperate with corresponding reflective curved surfaces to form a near-far light type, and does not need an additional mechanical structure to adjust the light-shielding plate.
  • the two-dimensional blended reflective surface and the iteration of the two light sources can form the far-near light type of the automotive headlamp required by the ECE regulations.
  • the precise heat dissipation structure and the novel reflective surface assembly structure are simple, reliable and compact.
  • the LED light effect is maximally utilized, energy efficient, and can be applied to LED matrix light source design of large headlights of various models.
  • Figure 1 is a schematic view of the structure of the headlight.
  • FIG. 2 is a perspective view of an LED light source module.
  • 3 is a cross-sectional view of the LED light source module.
  • FIG. 4 is a schematic diagram of the LED light source module array lighting when the automobile is running normally.
  • Fig. 5 is a schematic diagram showing the illumination of the LED light source module array when the vehicle speed is 80-120 km/h.
  • Fig. 6 is a schematic view showing the illumination of the LED light source module array when the vehicle speed is 40 to 60 km/h.
  • Fig. 7 is a schematic view showing the illumination of the LED light source module array when the vehicle speed is 30 km/h.
  • FIG. 8 is a schematic diagram of the LED light source module array lighting when the vehicle speed is 20 km/h.
  • FIG. 9 is a schematic diagram of the upper and lower polarizing fill light unit and the LED light source module.
  • Figure 10 is a block diagram of the closed-loop adaptive follow-up control system.
  • Figure 11 is a space coordinate diagram of the LED light source.
  • Figure 12 is a meshing of the low beam receiving surface.
  • Figure 13 is a high beam receiving surface mesh division.
  • An adaptive far and near light integrated LED multi-module headlight comprising a near-and-near optical follow-up adaptive light type control system, a compensation light system and a color temperature control system.
  • the near-and-near optical follow-up adaptive light type control system includes an LED light source module array 1 , and the LED light source module array 1 includes seven LED light source modules, wherein three LEDs near the center of the vehicle body The light source modules are arranged parallel to each other and the optical axis is parallel with the center of the vehicle body to form a straight light source 11; the remaining four LED light source modules disposed outside the straight light source 11 constitute a steering light source 12, and the optical axis of the LED light source module in the steering light source 12 The angle between the center and the center of the vehicle body increases from the inside to the outside.
  • the angles of the four LED light source modules of the steering light source 12 from the inside to the outside are 13 to 17 degrees and 17 to 21 degrees from the center line of the vehicle body. , 28 to 32 ° and 40 to 44 °.
  • the automobile headlight of the invention has a unique far and near light integrated by 7 previous patents.
  • the modules form an array of LED light sources.
  • Each of the independent near-and-outer tube modules in the array of light sources can be individually controlled to drive (several or several of the light-emitting units can be illuminated by the superposition of light to meet the illumination intensity and width requirements of the visible area under different vehicle conditions).
  • the compensating optical system includes a plurality of upper polarizing auxiliary light-filling units 2 located above the near-near optical follow-up adaptive light type control system and a plurality of low-intensity optical follow-up adaptive light type control systems.
  • the upper polarization-assisted light-filling unit 2 includes an upper polarized LED light source and an upper polarized light reflecting surface, the upper polarized LED light source is located at the bottom of the upper polarized light reflecting surface, and the light emitted by the upper polarized LED light source passes through the upper polarized light.
  • the reflection of the reflective surface is such that the distribution area of the light exit angle is 6-10 degrees from the ground plane to automatically compensate the illumination area of the vehicle during deceleration, heavy load or hill climbing;
  • the lower polarization auxiliary fill light unit 3 includes lower polarization The LED light source and the lower polarized light reflecting surface, the lower polarized LED light source is located at the top of the lower polarized light reflecting surface, and the light emitted by the lower polarized LED light source is reflected by the lower polarizing reflecting surface, so that the distribution angle of the light exiting angle is 6 to 10° with the ground plane. To automatically compensate for the illuminated area of the vehicle during deceleration and downhill.
  • the color temperature control system includes a plurality of front fog lamp LED light sources 4, and the front fog lamp LED light source 4 includes an LED having a color temperature of 2700K, an LED having a color temperature of 7000K, and a fog lamp reflector.
  • the input values of the vehicle light intensity and color temperature sensor, the haze dust sensor, and the rain and snow sensor are given to the MCU.
  • the integrated algorithm output instruction of the MCU is applied to the intelligent lighting driving system of the LED light source of the fog lamp, and the yellow LED light source of two different color temperatures is adjusted by the PWM dimming algorithm output of the intelligent light source driving module of the fog lamp to mix the light output vehicle.
  • the best warning fog light color temperature and brightness in the driving environment which greatly improves the safety and warning function of the car when driving in a complex environment, and gives the adjacent car a more distinct driving position indication signal.
  • the LED light source module includes a first LED light source 112 , a first curved reflector 114 matched with the first LED light source 112 , a second LED light source 111 , and a second LED light source 111 .
  • the first LED light source 112 and the second LED light source 111 each include an LED chip, a circuit board and a heat sink, the circuit board is mounted on the heat sink, the middle of the circuit board is hollowed out, and the corresponding circuit board on the heat sink Forming a mounting plane, the LED chip is fixed on the mounting plane; the surface of the circuit board is provided with a pad, and the LED chip is connected to the pad through a gold wire; the hollow portion of the circuit board and the mounting plane form a concave a groove filled with fluorescence Silica gel.
  • the manufacturing method of the first LED light source 112 and the second LED light source 111 includes the following steps:
  • the high-reflection organic glue is poured into the hollowed out along the injection hole of the circuit board, so that the surrounding area around the LED chip to the hollow area of the circuit board is completely covered, the amount of glue filling does not exceed the surface of the LED chip, and the glue is solidified by heating;
  • the LED chip of the invention is directly connected with the lamp radiator for heat dissipation, reduces the junction temperature of the LED chip with greatly reduced thermal resistance, and the volume of the LED can be made smaller, and the purpose of placing the plurality of LED light source modules of the invention can be achieved. .
  • the highly reflective silicone material effectively reduces unnecessary light loss and greatly increases the light energy in the directivity range.
  • the independent far and near light integrated automobile headlight light-emitting unit of the invention adopts two independent LED light sources to cooperate with corresponding reflective curved surfaces to form a near-far light type, and does not need an additional mechanical structure to adjust the light-shielding plate, and only needs two mixed sweeps.
  • the slightly reflective surface and the iteration of the two light sources can form the far-near light type of the automotive headlamp required by the ECE regulations.
  • the assembly structure of the precise heat dissipation structure and the novel reflective surface is simple, reliable and compact, and the LED light effect is maximized.
  • the use of the limit, high efficiency and energy saving can be applied to the LED matrix light source design of the large headlights of various models.
  • the design method of the first curved reflector 114 includes the following steps:
  • Dividing the solid angle of the LED light source setting the LED as the coordinate origin, as shown in Fig. 11, ⁇ is the angle between the plane of the outgoing ray and the X-axis and the XOZ plane, and ⁇ is the angle between the outgoing ray and the X-axis; Uniformly discretizing the solid angle of the light source, dividing ⁇ into i parts, and dividing each of ⁇ into j parts to obtain an array of ⁇ (i) and ⁇ (i, j);
  • the luminous flux in each small solid angle is:
  • each alpha angle corresponds to a length y(i, j+1)-y(i,j) and a width x(i+1)-x(i)
  • the rectangular area the total energy of each rectangular area is:
  • Etotal 1 E c ⁇ [x(i+1)-x(i)] ⁇ [y(i,j+1)-y(i,j)] (3)
  • E c represents the illuminance value. Since the illuminance values of the regions I, II, III and IV are different, the preset illuminance E and the illuminance control factor ⁇ are different for different regions:
  • k takes a one-to-one correspondence with the I, II, III, and IV regions, and the ⁇ (k) values are different, and need to be continuously adjusted in the calculation according to the simulation results to reach the standard Claim;
  • the height is y(i, j+1)-y(i, j), and the bottom side is x(i+1)-x(i),
  • the total energy of the area is:
  • the energy emitted by the LED source is equal to the energy received on the receiving surface, which is obtained by the law of conservation of energy:
  • the law of the point on the free surface can be obtained by the law of the law of deflection.
  • the tangential plane is used to obtain the tangential plane.
  • the coordinates of the upper and lower points of the curve are obtained by finding the intersection of the plane and the incident ray. .
  • the vector form of the law of catadiopism can be expressed as:
  • n is the refractive index, where n is 1, Is the incident ray unit vector, the outgoing ray unit vector, and the unit normal vector;
  • the design method of the second curved reflector 113 includes the following steps:
  • the design method of the high beam part is the same as the low beam, but due to different illumination requirements, the meshing and illumination control factors of the receiving surface are designed as follows:
  • the center should have a high brightness and gradually weaken to the surrounding, divided according to the way shown in Figure 13, and the right-angle coordinates of the receiving surface are also divided into i parts in the x direction, for each x, Dividing the y direction into j parts, and obtaining an array of x(i) and y(i,j) in one-to-one correspondence with the ⁇ (i) and ⁇ (i,j) arrays in the solid angle of the light source in the rectangular coordinate system of the receiving surface;
  • the grid ring line is set to have an illuminance control factor for different loop lines:
  • the coordinates of each point on the high-beam free-form surface reflector can be obtained.
  • the calculated reflector surface is modeled and simulated, and the simulation results are analyzed.
  • the parameter settings of the illuminance control factor can be modified to optimize and modify, and the ideal model is finally obtained.
  • the emitted light of the LED is distributed in the predetermined light distribution range after passing through the reflector and the lens, and meets the requirements of relevant regulations.
  • Light energy utilization of the LED optical system ideally, the ratio of the amount of light received on the target surface to the total number of rays emitted by the LED source is defined as the near-light ratio of 70% or more, and the high beam is 85%. the above.
  • the near-and-near-light adaptive light-type control system, the compensation light system, and the color temperature control system in the headlight are controlled and coordinated by a closed-loop adaptive follow-up control system, which includes a body sensor group, Body control MCU and headlight AFS sub-system AU, body sensor group and body control MCU connection, body master control MCU through headlamp AFS sub-system AU control far and near light follow-up adaptive light control system, compensation light System and color temperature control system;
  • the body sensor group includes a body speed sensor, a body tilt/corner sensor, a body heavy load sensor, a body road condition vibration sensor, a steering wheel angle sensor, a rain sensor, a smog/ Snow sensor and downtown environment sensor.
  • the adaptive random control system illuminates the LEDs of the two large headlights on the left and right sides through the body MCU command and the corresponding drive control system.
  • the individual modules in the light source module array 1 enable the LED headlamps invented by the patent to emit road conditions that best meet the comfortable brightness of safe driving under different driving conditions, which can greatly improve the safety and comfort of the driver. degree. Optimized combination to illuminate different LED light source module arrays 1 group can meet and optimize the following safe driving functions:
  • the left headlight and the right headlight in the normal driving only need to illuminate three independent LED light source modules in the middle of the respective light source array near the vehicle body to meet the regulatory requirements.
  • the headlights are close to the brightness of the light, the illumination and illumination area regulations "GB 25991-2010 automotive LED headlamps” and "GB 4599-2007 automotive filament bulb headlamps” requirements.
  • the three independent LED light and near-light integrated modules are installed in parallel, and the light intensity and illumination and the illuminated areas are mutually enhanced to meet regulatory requirements.
  • the body light intensity sensor senses that the light intensity data of the light from the opposite car is transmitted to the body control MCU, and the body control MCU control command drives the lamp control unit module EU to close the left side.
  • One or more separate LED light source modules of parallel light source 11 installed in parallel to reduce the overall luminous intensity of the matrix light source on the left side, and the brightness of the matrix light source on the right side is unchanged, thereby preventing strong high beam Light affects the safe driving of the driver opposite.
  • the LED light source matrix that can be independently controlled is not used, the vehicle that is driven on the opposite side is completely placed under strong light, which seriously affects the safety of the driver at night.
  • the invention can separately optimize and control each LED light source module, and under the comprehensive control of the body sensor and the body electronic control system, the single headlight of the left side of the vehicle can be automatically turned off according to the driving condition of the vehicle opposite to the vehicle at night.
  • a plurality of independent LED light source modules narrow the light-emitting width of the left front headlight of the vehicle body by a2 ⁇ a1 for safe driving of the opposite vehicle; when the vehicle meets, the multi-point LED light source array of the left headlight is instantaneously and automatically Return to normal light intensity and width range a2.
  • the minimum turning radius is 570 m and the minimum parking line of sight is 210 m.
  • the vehicle body is turned 11° in a safe and reliable parking line of sight; It is 100 km/h, the minimum turning radius is 360 m, and the minimum parking line of sight is 160 m.
  • the body is turned 13° in a safe and reliable parking line of sight; at a speed of 80 km/h, the minimum turning radius At 220 meters, the minimum parking line of sight is 110 meters. At this time, the body is turned 14° in a safe and reliable parking line of sight.
  • the first LED light source module in the steering light source 12 increases the illumination area of the left and right sides of the vehicle body by 15° to increase the visible area of the driver's turn at night.
  • the required speed is 60 km / h
  • the minimum turning radius is 115 m
  • the minimum parking line of sight is 75 m.
  • the body turns to 19 °;
  • the minimum turning radius is 60 m and the minimum parking line of sight is 40 m.
  • the body turns to 19° in a safe and reliable parking line of sight.
  • the first and second LED light source modules in the steering light source 12 are increased by the driving control system of the headlight LED light source module to compensate the visible area of the steering by 19°, thereby increasing the driver's
  • the small radius is turned at a speed of 60 to 40 kilometers, the visible areas on the left and the right sides are increased by 19°.
  • the required speed is 30 km/h
  • the minimum turning radius is 30 m
  • the minimum parking line of sight is 30 m.
  • the vehicle body is turned 30° in a safe and reliable parking line of sight.
  • the vehicle headlight follow-up control system respectively increases the first to third LED light source modules in the turning light source 12, compensating for the visible area of the steering when the steering is 30°, and increasing the driver at 30.
  • the visible areas on the left and right sides are each increased by 30°.
  • the required speed is 20 km/h
  • the minimum turning radius is 30 m
  • the minimum parking line of sight is 15 m.
  • the vehicle body is turned 42° in a safe and reliable parking line of sight.
  • the vehicle headlight follow-up control system respectively increases all the LED light source modules in the steering light source 12, compensating for the visible area of the steering when the steering is 42°, and increasing the driver's speed at 20 km.
  • the visible areas on the left and right sides are each increased by 42°.
  • the follow-up adaptive control system of the body control MCU automatically acquires the body The comprehensive data of the speed sensor, the steering wheel angle sensor and the body yaw rate and angle sensor, and use these data to calculate the turning radius of the car and the required illuminance area width value of the side of the vehicle, and output the corresponding driving command to the LED car.
  • the driving module of the lamp sequentially turns on the four independent LED light source modules attached to the steering light source 12 according to the best fit to widen the visible area and the light intensity of the left side of the driver when turning left.
  • the signal of the body light intensity is transmitted to the body control MCU through the controller, and the control program of the body control MCU controls the output current of the driving circuit of the LED light source module array 1 to pass Increase the driving power of each LED light source module to enhance the brightness and illumination of the headlights to improve the visibility and visibility of the car when driving in harsh rain, snow and fog.
  • the values of the various sensors of the adaptive system of the vehicle acceleration, deceleration, heavy load, climbing and urban road driving are outputted to the execution unit by the integrated comparison algorithm of the MCU control system, and the intelligence of the light source of the far and near light LED Illuminating the drive system and the plurality of independent far and near light sources of the whole lamp, and the upper and lower sets of deflected auxiliary fill light sources to improve the lateral light shape width of the entire large headlight, and to illuminate the distance and height of the whole lamp downward or upward.
  • the data of the body speed sensor is transmitted to the main control MCU of the vehicle body.
  • the upper and lower polarization auxiliary light source module that selects the large headlight by the vehicle body control system increases the illumination area of the large headlight up or down. Expanded to improve the best match of the visible area of the driver while driving.
  • the light emitted by the LED light source is reflected by the mirror surface of the reflector, so that the distribution angle of the light exit angle and the ground plane are at an angle of 6 to 10, to automatically compensate the car for deceleration, heavy load or hill climbing.
  • the area of the light is reflected by the mirror surface of the reflector, so that the distribution angle of the light exit angle and the ground plane are at an angle of 6 to 10, to automatically compensate the car for deceleration, heavy load or hill climbing.
  • the light emitted by the LED light source is reflected by the mirror surface of the reflector, so that the distribution angle of the light exit angle and the ground plane are at an angle of 6 to 10, to automatically compensate the car at the speed, downhill Light area.
  • the 14 independent LED light source modules of the left and right headlights are separately optimized by the integrated control module of the body control MCU, and the left and right fronts are respectively
  • the up and down polarization fill light unit of the lamp is used to output an optimal adaptive follow-up visual driving area to improve driving safety and comfort.

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Abstract

一种自适应远近光一体LED多模组前照灯，包括远近光随动自适应光型控制系统、补偿光系统和色温控制系统；所述远近光随动自适应光型控制系统包括LED光源模组阵列，所述LED光源模组阵列包括若干LED光源模组，其中包括两个以上相互平行设置且光轴与车身中心平行的LED光源模组形成直行光源，包括一个以上设置在直行光源外侧且光轴与车身中心呈锐角夹角的LED光源模组形成转向光源，转向光源中的LED光源模组的光轴与车身中心之间的夹角从内往外依次增大。通过设置多个独立的LED光源模组作为前照灯，车辆在直行或转弯时，通过控制不同的LED光源模组点亮，从而达到实现直行时的远近光光斑和转弯时的光型随动，以获得更好的光照角度。

Description

一种自适应远近光一体LED多模组前照灯 技术领域
本发明涉及LED领域，尤其是一种自适应远近光一体LED多模组前照灯。
背景技术
汽车前照灯是汽车照明系统中的重要组成部分，为汽车行驶提供主动的安全防护。大功率白光LED(Light Emitting Diode)以其体积小、光效高、响应快、节能环保和结构稳定等优势，正逐步发展为汽车前照灯的新一代绿色光源，采用LED光源替换传统光源，是汽车前照灯技术发展的必然趋势。
传统前照灯受传统光源360度发光的影响，光线的利用率较低且容易产生眩光，为提高照明光通量往往还需增加补光单元才能达到较好的道路照明效果,出现光效低、体积大和眩光严重等情况，然而，采用LED可以提高光源的光线利用率并减少眩光，还可以大大缩小前照灯的体积提升美观性。从近年来LED前照灯产品化的情况来看，大部分LED前照灯都通过单独设计远光灯和近光灯，或者采用多个光学单元相互补光的方式实现前照灯系统的设计。因此，本设计提出一种前照灯一体式的光学设计方案，将远光和近光功能集成到同一个光学系统中，实现LED远近光一体前照灯的设计。
一体化前照灯设计较好地解决了集成化问题，但是在道路照明智能化方面还有不足，面对不同道路环境的适应能力不足。随着汽车智能化技术的发展，汽车照明系统智能化将是未来的发展方向。由于LED具有响应速度快和易于控制等特点，相比传统光源更容易实现智能化控制。虽然在传统光源前照灯系统中也有基于自适应系统AFS(Adaptive Front-lighting System)的前照灯，但是其主要通过随向转动技术在行驶过程中调整灯头上下、左右的照射方向，或者通过不同截光装置产生的不同光型，以上两种方式主要通过机械方式实现自适应照明，在功能方面有较多不足之处，智能化程度不高。为此，本设计提出一种基于LED光源模组阵列的自适应光型控制系统、自动补偿光和色温控制系统，提高前照灯的智能化程度，实现不同道路环境的照射要求。整个系统实现模组化设计，结构简单，控制方便。
发明内容
本发明所要解决的技术问题是提供一种自适应远近光一体LED多模组前照灯，提高灯具的集成化和智能化，结构简单，体积小，制造成本低。
为解决上述技术问题，本发明的技术方案是：一种自适应远近光一体LED多模组前照灯，包括远近光随动自适应光型控制系统、补偿光系统和色温控制系统；
所述远近光随动自适应光型控制系统包括LED光源模组阵列，所述LED光源模组阵列包括若干LED光源模组，其中包括两个以上相互平行设置且光轴与车身中心平行的LED光源模组形成直行光源，包括一个以上设置在直行光源外侧且光轴与车身中心呈锐角夹角的LED光源模组形成转向光源，转向光源中的LED光源模组的光轴与车身中心之间的夹角从内往外依次增大；直行光源比转向光源靠近车身中心；当车辆正常行驶时，直行光源点亮；当车辆夜间会车时，关闭直行光源中的一个或多个LED光源模组以减弱直行光源光照强度；当车辆夜间转弯时，点亮转向光源中的一个或多个LED光源模组；所述LED光源模组包括第一LED光源、与第一LED光源配合的第一曲面反射器、第二LED光源、与第二LED光源配合的第二曲面反射器和凸透镜，单独点亮第一LED光源时，LED光源模组打出近光光型，当第一LED光源和第二LED光源同时点亮时，LED光源模组打出远光光型；
所述补偿光系统包括若干位于远近光随动自适应光型控制系统上方的上偏光辅助补光单元和若干位于远近光随动自适应光型控制系统下方的下偏光辅助补光单元；所述上偏光辅助补光单元包括上偏光LED光源和上偏光反光面，上偏光LED光源位于上偏光反光面的底部，上偏光LED光源发出的光线经过上偏光反光面的反射，使得出光角度的分布区域与地平面的成6～10°，来自动补偿车辆在减速、重载或爬坡时的光照区域；所述下偏光辅助补光单元包括下偏光LED光源和下偏光反光面，下偏光LED光源位于下偏光反光面的顶部，下偏光LED光源发出的光线经过下偏光反光面的反射，使得出光角度的分布区域与地平面的成6～10°，来自动补偿车辆在减速和下坡时的光照区域。
本发明通过设置多个独立的LED光源模组作为前照灯，车辆在直行或转弯时，通过控制不同的LED光源模组点亮，从而达到实现直行时的远近光光斑和转弯时的光型随动，以获得更好的光照角度。偏光补偿系 统专门针对车辆在加速或减速，重载，爬坡和城市道路的行驶。
作为改进，所述第一LED光源和第二LED光源均包括LED芯片、线路板和散热器，所述线路板安装在散热器上，所述线路板的中间镂空，所述散热器上对应线路板镂空处形成安装平面，所述LED芯片固定在所述安装平面上；所述线路板表面设有焊盘，所述LED芯片通过金线与焊盘连接；线路板的镂空处与安装平面形成凹槽，所述凹槽内填充有荧光硅胶。
作为改进，第一LED光源和第二LED光源的制造方法包括以下步骤：
(1)在散热器的顶部预加工出一个安装平面；
(2)将线路板中间镂空并贴合在散热器上，镂空处与预加工出的安装平面对应；
(3)在线路板的表面设置焊盘，焊盘采用表面沉金处理；
(4)将若干LED芯片按串并方式置于线路板中间镂空区域处的散热器安装平面上，粘接LED芯片的粘接剂使用导热系数25W/m*k的银胶；
(5)将LED芯片串并线路的正负极与线路板上的焊盘连接；
(6)将高反射有机胶沿线路板注胶孔灌入镂空处，使LED芯片周围至线路板镂空周围区域全面覆盖，灌胶量不超出LED芯片表面，加热使胶体固化；
(7)将荧光粉硅胶的混合物灌封LED芯片和金线；
(8)加温固化LED封装胶。
本发明LED芯片直接与车灯散热器连接进行散热，减少热阻极大的降低的LED芯片的结温，LED的体积可以做得更小，能够实现本发明放置多个LED光源模组的目的。高反射有机硅材质有效减少不必要的光损失，大幅度提高指向性范围内的光能量。
作为改进，所述第一曲面反射器的设计方法包括以下步骤：
(1)划分LED光源立体角：将LED设为坐标原点，α为出射光线与X轴组成的平面与XOZ平面的夹角，β为出射光线与X轴的夹角；对光源的立体角进行均匀离散化，把α等分成i份，对于每一个α，都将β等分成j份，得到α(i)和β(i,j)的数组；
(2)划分接收面网格：根据配光要求，对应于光源立体角的划分，接收面的直角坐标也相应的在x方向上分成i份，对于每一份x，都将y方向分成j份，在接收面直角坐标系中得到与光源立体角中α(i)和β(i,j)数组一一对应的x(i)和y(i,j)数组；
(3)计算自由曲面上离散点的坐标：设给定的光源的光通量为Q，因为使用的LED光源为朗伯源，其光强分布为中心光强的余弦分布，朗伯光源的中心光强为I0，由与光源中心轴夹角为α1与光源中心轴夹角为α2的入射光线之间的能量可以表示为：
Figure PCTCN2016089990-appb-000001
每一小份立体角内的光通量为：
Figure PCTCN2016089990-appb-000002
由于每一小份立体角内的取值是已知的，那么根据公式(1)，(2)计算出中心光强I0和每一小份立体角内的能量值大小；
在目标照明区域水平线下的部分，每一份α角所对应的是一个长为y(i,j+1)-y(i,j)，宽为x(i+1)-x(i)的矩形区域，每个矩形区域的总能量为：
Etotal1＝Ec·[x(i+1)-x(i)]·[y(i,j+1)-y(i,j)]      (3)
式中，Ec表示照度值，由于区域Ⅰ、Ⅱ、Ⅲ、Ⅳ区域的照度值各不相同，故预设照度E，照度控制因子γ，对于不同区域有：
Ec＝E·γ(k)   k＝1,2,3,4             (4)
其中0≤γ(k)≤1，k的取值与Ⅰ、Ⅱ、Ⅲ、Ⅳ区域一一对应，且γ(k)值各不相同，需根据模拟结果在计算中不断调整以达到标准的要求；
在目标照明区域水平线上的部分，划分时存在三角形区域，其高为y(i,j+1)-y(i,j)，底边为x(i+1)-x(i)，该区域的总能量为：
Figure PCTCN2016089990-appb-000003
在不考虑能量的损耗的情况下，LED光源发出的能量等于接收面上
接收到的能量，由能量守恒定律可得：
Energy＝Etotal1+Etotal2             (6)
假设光线在与反射器作用时发生全反射，由折反射定律可得到自由曲面上点的法向量，利用这个法向量求得切平面，通过求切平面与入射光线的交点得到曲线上下一点的坐标。折反射定律的矢量形式可表示为：
Figure PCTCN2016089990-appb-000004
其中n为折射率，这里n取值为1，
Figure PCTCN2016089990-appb-000005
为入射光线单位向量、出射光线单位向量、单位法向量；
在迭代计算时，首先需要确定一个计算的起始点，由这个初始点算出一条边界曲线，再由边界曲线的上的每一个点为初始点计算出整个自由曲面。
本发明独立的远近光一体的汽车前照灯发光单元，采用两个独立的LED光源与对应的反光曲面配合，形成远近光型，无需附加机械结构来 调整遮光板，只需通过俩个混成扫略的反光曲面以及两个光源的迭代就可形成ECE法规要求的汽车前照灯的远近光光型，精准的散热结构和新颖的反光曲面的组装结构简单可靠紧凑，LED的光效得到了最大限度的利用，高效节能，可适用于各种不同车型的大前灯的LED矩阵光源设计。
作为改进，所述第二曲面反射器的设计方法包括以下步骤：
(1)划分接收面网格：远光照度要求，中心处应具有较高亮度，并向周围逐渐减弱，将接收面的直角坐标也相应的在x方向上分成i份，对于每一份x，都将y方向分成j份，在接收面直角坐标系中得到与光源立体角中α(i)和β(i,j)数组一一对应的x(i)和y(i,j)数组；
(2)照度控制因子设置：由于远光要求中心照度高，并向周围逐渐减弱，所以所划分网格环线设置照度控制因子，对于不同环线有：
Ec＝E·γ(k)   k＝1,2,3,4；
(3)计算自由曲面上离散点的坐标：设给定的光源的光通量为Q，因为使用的LED光源为朗伯源，其光强分布为中心光强的余弦分布，朗伯光源的中心光强为I0，由与光源中心轴夹角为α1与光源中心轴夹角为α2的入射光线之间的能量可以表示为：
Figure PCTCN2016089990-appb-000006
每一小份立体角内的光通量为：
Figure PCTCN2016089990-appb-000007
由于每一小份立体角内的取值是已知的，那么根据公式(1)，(2)计算出中心光强I0和每一小份立体角内的能量值大小；
在目标照明区域水平线下的部分，每一份α角所对应的是一个长为y(i,j+1)-y(i,j)，宽为x(i+1)-x(i)的矩形区域，每个矩形区域的总能量为：
Etotal1＝Ec·[x(i+1)-x(i)]·[y(i,j+1)-y(i,j)]      (3)
式中，Ec表示照度值，由于区域Ⅰ、Ⅱ、Ⅲ、Ⅳ区域的照度值各不同，其中0≤γ(k)≤1，k的取值与Ⅰ、Ⅱ、Ⅲ、Ⅳ区域一一对应，且γ(k)值各不相同，需根据模拟结果在计算中不断调整以达到标准的要求；
在目标照明区域水平线上的部分，划分时存在三角形区域，其高为y(i,j+1)-y(i,j)，底边为x(i+1)-x(i)，该区域的总能量为：
Figure PCTCN2016089990-appb-000008
在不考虑能量的损耗的情况下，LED光源发出的能量等于接收面上接收到的能量，由能量守恒定律可得：
Energy＝Etotal1+Etotal2             (6)
假设光线在与反射器作用时发生全反射，由折反射定律可得到自由曲 面上点的法向量，利用这个法向量求得切平面，通过求切平面与入射光线的交点得到曲线上下一点的坐标。折反射定律的矢量形式可表示为：
Figure PCTCN2016089990-appb-000009
其中n为折射率，这里n取值为1，
Figure PCTCN2016089990-appb-000010
为入射光线单位向量、出射光线单位向量、单位法向量；
在迭代计算时，首先需要确定一个计算的起始点，由这个初始点算出一条边界曲线，再由边界曲线的上的每一个点为初始点计算出整个自由曲面。
作为改进，得出的自由曲面的模型建立方法：通过前面所述设计方法，迭代计算出自由曲面反射器的离散坐标点，将些离散点保存为文本文件并导入三维制图软件SolidWorks中，拟合成为平滑的曲面，得到反射器的实体模型，并将其导入光学仿真软Lucidshape中，设置好透镜的材料属性、光源的属性以及接收面的属性，对所得的模型进行光线追迹。
作为改进，所述LED光源模组阵列一共设有七个LED光源模组，其中三个LED光源模组为直行光源，四个LED光源模组为转向光源。
作为改进，所述转向光源的四个LED光源模组中，从内往外依次与车身中心线的夹角为13～17°、17～21°、28～32°和40～44°。
作为改进，色温控制系统包括若干前雾灯LED光源，所述前雾灯LED光源包括色温为2700K的LED、色温为7000K的LED和雾灯反光杯。
作为改进，前照灯还包括闭环自适应随动控制系统，其包括车身感应器组、车身总控MCU和前照灯AFS分系统AU，车身感应器组与车身总控MCU连接，车身总控MCU通过前照灯AFS分系统AU控制远近光随动自适应光型控制系统、补偿光系统和色温控制系统；所述车身感应器组包括车身速度感应器、车身倾角/转角感应器、车身重载感应器、车身路况震动感应器、方向盘转角感应器、下雨量感应器、雾霾/下雪感应器和闹市环境感应器。
本发明与现有技术相比所带来的有益效果是：
本发明通过设置多个独立的LED光源模组作为前照灯，车辆在直行或转弯时，通过控制不同的LED光源模组点亮，从而达到实现直行时的远近光光斑和转弯时的光型随动，以获得更好的光照角度。偏光补偿系统专门针对车辆在加速或减速，重载，爬坡和城市道路的行驶。本发明独立的远近光一体的汽车前照灯发光单元，采用两个独立的LED光源与对应的反光曲面配合，形成远近光型，无需附加机械结构来调整遮光板， 只需通过俩个混成扫略的反光曲面以及两个光源的迭代就可形成ECE法规要求的汽车前照灯的远近光光型，精准的散热结构和新颖的反光曲面的组装结构简单可靠紧凑，LED的光效得到了最大限度的利用，高效节能，可适用于各种不同车型的大前灯的LED矩阵光源设计。
附图说明
图1为前照灯结构示意图。
图2为LED光源模组立体图。
图3为LED光源模组剖视图。
图4为汽车正常行驶时LED光源模组阵列点亮的示意图。
图5为车速80～120千米/小时转弯时LED光源模组阵列点亮的示意图。
图6为车速40～60千米/小时转弯时LED光源模组阵列点亮的示意图。
图7为车速30千米/小时转弯时LED光源模组阵列点亮的示意图。
图8为图6为车速20千米/小时转弯时LED光源模组阵列点亮的示意图。
图9为上下偏光补光单元配合LED光源模组的示意图。
图10为闭环自适应随动控制系统结构框图。
图11为LED光源空间坐标图。
图12为近光接收面网格划分。
图13为远光接收面网格划分。
具体实施方式
下面结合说明书附图对本发明作进一步说明。
一种自适应远近光一体LED多模组前照灯，包括远近光随动自适应光型控制系统、补偿光系统和色温控制系统。
如图1所示，所述远近光随动自适应光型控制系统包括LED光源模组阵列1，所述LED光源模组阵列1包括七个LED光源模组，其中靠近车身中心的三个LED光源模组相互平行设置且光轴与车身中心平行组形成直行光源11；其余设置在直行光源11外侧的四个LED光源模组组成转向光源12，转向光源12中的LED光源模组的光轴与车身中心之间的夹角从内往外依次增大，所述转向光源12的四个LED光源模组中，从内往外依次与车身中心线的夹角为13～17°、17～21°、28～32°和40～44°。本发明汽车前照灯共由7个前面专利所描述独创的远近光一体 式模组组成LED光源阵列。光源阵列中的每个独立远近管模块可以单独控制驱动(可以同时或点亮其中的几个发光单元通过光线的叠加来满足不同车况下的可视区域的照明强度和宽度的要求)。
如图1、9所示，所述补偿光系统包括若干位于远近光随动自适应光型控制系统上方的上偏光辅助补光单元2和若干位于远近光随动自适应光型控制系统下方的下偏光辅助补光单元3；所述上偏光辅助补光单元2包括上偏光LED光源和上偏光反光面，上偏光LED光源位于上偏光反光面的底部，上偏光LED光源发出的光线经过上偏光反光面的反射，使得出光角度的分布区域与地平面的成6～10°，来自动补偿车辆在减速、重载或爬坡时的光照区域；所述下偏光辅助补光单元3包括下偏光LED光源和下偏光反光面，下偏光LED光源位于下偏光反光面的顶部，下偏光LED光源发出的光线经过下偏光反光面的反射，使得出光角度的分布区域与地平面的成6～10°，来自动补偿车辆在减速和下坡时的光照区域。
如图1所示，色温控制系统包括若干前雾灯LED光源4，所述前雾灯LED光源4包括色温为2700K的LED、色温为7000K的LED和雾灯反光杯。当汽车在地球上不同经纬度，以及不同程度的雾霾和雨雪天气行驶时，通过车身光强和色温感应器，雾霾沙尘感应器，以及雨雪量感应器的输入数值给MCU，由MCU的综合算法输出指令给雾灯的LED光源的智能点亮驱动系统，通过雾灯的智能光源驱动模块的PWM调光算法输出来调节两种不同色温的黄色LED光源以混光输出汽车所在的行驶环境中的最佳警示雾灯的色温和亮度，从而大大的提高汽车在复杂环境中行驶时的安全性和警示作用，给相邻汽车已更加鲜明的行车位置指示信号。
如图2、3所示，所述LED光源模组包括第一LED光源112、与第一LED光源112配合的第一曲面反射器114、第二LED光源111、与第二LED光源111配合的第二曲面反射器113和凸透镜115；第一曲面反射器114位于第二曲面反射器113的前方，单独点亮第一LED光源112时，LED光源模组打出近光光型，当第一LED光源112和第二LED光源111同时点亮时，LED光源模组打出远光光型。
所述第一LED光源112和第二LED光源111均包括LED芯片、线路板和散热器，所述线路板安装在散热器上，所述线路板的中间镂空，所述散热器上对应线路板镂空处形成安装平面，所述LED芯片固定在所述安装平面上；所述线路板表面设有焊盘，所述LED芯片通过金线与焊盘连接；线路板的镂空处与安装平面形成凹槽，所述凹槽内填充有荧光 硅胶。
第一LED光源112和第二LED光源111的制造方法包括以下步骤：
(1)在散热器的顶部预加工出一个安装平面；
(2)将线路板中间镂空并贴合在散热器上，镂空处与预加工出的安装平面对应；
(3)在线路板的表面设置焊盘，焊盘采用表面沉金处理；
(4)将若干LED芯片按串并方式置于线路板中间镂空区域处的散热器安装平面上，粘接LED芯片的粘接剂使用导热系数25W/m*k的银胶；
(5)将LED芯片串并线路的正负极与线路板上的焊盘连接；
(6)将高反射有机胶沿线路板注胶孔灌入镂空处，使LED芯片周围至线路板镂空周围区域全面覆盖，灌胶量不超出LED芯片表面，加热使胶体固化；
(7)将荧光粉硅胶的混合物灌封LED芯片和金线；
(8)加温固化LED封装胶。
本发明LED芯片直接与车灯散热器连接进行散热，减少热阻极大的降低的LED芯片的结温，LED的体积可以做得更小，能够实现本发明放置多个LED光源模组的目的。高反射有机硅材质有效减少不必要的光损失，大幅度提高指向性范围内的光能量。
本发明独立的远近光一体的汽车前照灯发光单元，采用两个独立的LED光源与对应的反光曲面配合，形成远近光型，无需附加机械结构来调整遮光板，只需通过俩个混成扫略的反光曲面以及两个光源的迭代就可形成ECE法规要求的汽车前照灯的远近光光型，精准的散热结构和新颖的反光曲面的组装结构简单可靠紧凑，LED的光效得到了最大限度的利用，高效节能，可适用于各种不同车型的大前灯的LED矩阵光源设计。
所述第一曲面反射器114的设计方法包括以下步骤：
(1)划分LED光源立体角：将LED设为坐标原点，如图11所示，α为出射光线与X轴组成的平面与XOZ平面的夹角，β为出射光线与X轴的夹角；对光源的立体角进行均匀离散化，把α等分成i份，对于每一个α，都将β等分成j份，得到α(i)和β(i,j)的数组；
(2)划分接收面网格：如图12所示，根据配光要求，对应于光源立体角的划分，接收面的直角坐标也相应的在x方向上分成i份，对于每一份x，都将y方向分成j份，在接收面直角坐标系中得到与光源立体角中α(i)和β(i,j)数组一一对应的x(i)和y(i,j)数组；
(3)计算自由曲面上离散点的坐标：设给定的光源的光通量为Q，因 为使用的LED光源为朗伯源，其光强分布为中心光强的余弦分布，朗伯光源的中心光强为I0，由与光源中心轴夹角为α1与光源中心轴夹角为α2的入射光线之间的能量可以表示为：
Figure PCTCN2016089990-appb-000011
每一小份立体角内的光通量为：
Figure PCTCN2016089990-appb-000012
由于每一小份立体角内的取值是已知的，那么根据公式(1)，(2)计算出中心光强I0和每一小份立体角内的能量值大小；
在目标照明区域水平线下的部分，每一份α角所对应的是一个长为y(i,j+1)-y(i,j)，宽为x(i+1)-x(i)的矩形区域，每个矩形区域的总能量为：
Etotal1＝Ec·[x(i+1)-x(i)]·[y(i,j+1)-y(i,j)]      (3)
式中，Ec表示照度值，由于区域Ⅰ、Ⅱ、Ⅲ、Ⅳ区域的照度值各不相同，故预设照度E，照度控制因子γ，对于不同区域有：
Ec＝E·γ(k)   k＝1,2,3,4             (4)
其中0≤γ(k)≤1，k的取值与Ⅰ、Ⅱ、Ⅲ、Ⅳ区域一一对应，且γ(k)值各不相同，需根据模拟结果在计算中不断调整以达到标准的要求；
在目标照明区域水平线上的部分，划分时存在三角形区域，其高为y(i,j+1)-y(i,j)，底边为x(i+1)-x(i)，该区域的总能量为：
Figure PCTCN2016089990-appb-000013
在不考虑能量的损耗的情况下，LED光源发出的能量等于接收面上接收到的能量，由能量守恒定律可得：
Energy＝Etotal1+Etotal2             (6)
假设光线在与反射器作用时发生全反射，由折反射定律可得到自由曲面上点的法向量，利用这个法向量求得切平面，通过求切平面与入射光线的交点得到曲线上下一点的坐标。折反射定律的矢量形式可表示为：
Figure PCTCN2016089990-appb-000014
其中n为折射率，这里n取值为1，
Figure PCTCN2016089990-appb-000015
为入射光线单位向量、出射光线单位向量、单位法向量；
在迭代计算时，首先需要确定一个计算的起始点，由这个初始点算出一条边界曲线，再由边界曲线的上的每一个点为初始点计算出整个自由曲面。
第二曲面反射器113的设计方法包括以下步骤：
远光部分设计方法整体与近光相同，但由于不同的照度要求，其接收面网格划分与照度控制因子设计如下：
1、划分接收面网格
远光照度要求，中心处应具有较高亮度，并向周围逐渐减弱，按图13所示方式划分，同样将接收面的直角坐标也相应的在x方向上分成i份，对于每一份x，都将y方向分成j份，在接收面直角坐标系中得到与光源立体角中α(i)和β(i,j)数组一一对应的x(i)和y(i,j)数组；
2、照度控制因子设置
由于远光要求中心照度高，并向周围逐渐减弱，所以所划分网格环线设置照度控制因子，对于不同环线有：
Ec＝E·γ(k)   k＝1,2,3,4
按照近光自由曲面设计中离散点的求解方法以及计算步骤，可得出远光自由曲面反射器上每一个点的坐标。将计算得出的反射器曲面进行建模仿真，并对仿真结果进行分析，可适当修改照度控制因子的参数设置进行优化修改，并最终得出理想模型。
自由曲面模型的建立与仿真分析
通过前面所述设计方法，迭代计算出自由曲面反射器的离散坐标点，将些离散点保存为文本文件并导入三维制图软件SolidWorks中，拟合成为平滑的曲面，得到反射器的实体模型，并将其导入光学仿真软Lucidshape中，设置好透镜的材料属性、光源的属性以及接收面的属性，对所得的模型进行光线追迹。在仿真中我们选用OSRAM U1A5的LED芯片作为光源，反射器设置为完全反射面，透镜所用材料选用PC，其折射率约为1.586。用近光与远光的照度分布图，可以看出LED的出射光经反射器及透镜后分布在预定的光分布范围内，满足相关法规的要求。LED光学系统的光能利用率(理想情况下，定义光能利用率为目标面上接收到的光线数与LED光源发出的总光线数之比)近光在70％以上，远光在85％以上。
如图10所示，前照灯中的远近光随动自适应光型控制系统、补偿光系统和色温控制系统均通过闭环自适应随动控制系统进行控制和协调，其包括车身感应器组、车身总控MCU和前照灯AFS分系统AU，车身感应器组与车身总控MCU连接，车身总控MCU通过前照灯AFS分系统AU控制远近光随动自适应光型控制系统、补偿光系统和色温控制系统；所述车身感应器组包括车身速度感应器、车身倾角/转角感应器、车身重载感应器、车身路况震动感应器、方向盘转角感应器、下雨量感应器、雾霾/下雪感应器和闹市环境感应器。自适应随机控制系统通过车身MCU指令和对应的驱动控制系统来点亮左右两边的两个大前灯的LED 光源模组阵列1中的单独模块，从而使得本专利所发明的LED前照灯可在不同的行驶车况下发出最符合安全驾驶的舒适亮度的路况光照，可以大大提高司机驾驶的安全度和舒适度。优化组合点亮不同的LED光源模组阵列1群可以满足和优化以下安全驾驶功能：
1、正常行驶
如图4所示，正常行驶时左边的大前灯和右边的大前灯分别只需要点亮各自的光源阵列中的靠近车体中间的三个独立LED光源模组点亮以满足法规要求的大前灯远近光的亮度，照度和光照区域的法规《GB 25991-2010汽车用LED前照灯》以及《GB 4599-2007汽车用灯丝灯泡前照灯》的要求。
此中间的三组独立的LED远近光一体模组平行安装，光强和照度以及照亮区域互相加强，以满足法规要求。
2、夜间会车
夜间两车相会时，车身光强感应器感应到对面汽车射过来的光的光强数据传输到车身总控MCU，车身总控MCU的控制指令来驱动车灯控制单元模块EU来关闭左侧前照灯的1个或多个单独的平行安装的直行光源11的LED光源模组，以减弱左侧的矩阵光源的总体发光强度，右侧的矩阵光源亮度不变，从而防止远光的强光影响对面的司机的安全驾驶。通过实验对比可以知道：在没有使用可单独控制的LED光源矩阵时，对面行驶过来的车被完全置于强光之下，严重影响对面司机的夜间驾车安全。而本发明可单独优化控制每个LED光源模组，在车身传感器和车身电子控制系统综合调控下，可根据晚间会车时对面的车辆行驶路况来自动关闭本车的左边前照灯的单个或多个独立LED光源模组，把自己车身左前大灯的出光宽度变窄a2<a1，以便对面车辆的安全行驶；当辆车交汇过后，左边的前照灯的多点LED光源阵列又瞬间自动恢到正常的光照强度和宽度范围a2。
3、夜间转弯行车
根据JTG B01-2014公路工程技术标准要求：
Figure PCTCN2016089990-appb-000016
3.1车速80～120千米/小时，大半径转弯路况下的可视区域补光
根据JTG B01-2014的要求，在车速为120千米/时，最小转弯半径为570米，最小停车视距为210米，此时在安全可靠的停车视距内，车身转向11°；在车速为100千米/小时，最小转弯半径为360米，最小停车视距为160米，此时在安全可靠的停车视距内，车身转向13°；在车速为80千米/小时，最小转弯半径为220米，最小停车视距为110米，此时在安全可靠的停车视距内，车身转向14°。车身传感方向盘转向感应器，车身横摆感应器，和车身速度感应的数据传、传输给车身总控MCU，如图5所示，通过前照灯LED光源模组的驱动控制系统增加点亮转向光源12中的第一个LED光源模组，分别增加车身左右两边的照亮区域15°，以增加司机夜间转弯行车的可视区域。
3.2车速40～60千米/小时，小半径转弯路况下的可视区域补光
根据JTG B01-2014，要求在车速为60千米/小时，最小转弯半径为115米，最小停车视距为75米，此时在安全可靠的停车视距内，车身转向了19°；在车速为40千米/小时，最小转弯半径为60米，最小停车视距为40米，此时在安全可靠的停车视距内，车身转向了19°。如图6所示，通过前照灯LED光源模组的驱动控制系统增加点亮转向光源12中的第一和第二个LED光源模组，补偿转向时的可视区域19°，增加司机在60到40千米车速时小半径转弯时，左右两边的可视区域各增加19°。
3.3车速30千米/小时，30米小半径转弯路况下的可视区域补光
根据JTG B01-2014，要求在车速为30千米/小时，最小转弯半径为30米，最小停车视距为30米，此时在安全可靠的停车视距内，车身转向了30°。如图7所示，此时车身前照灯随动控制系统分别增加点亮转向光源12中的第一至第三个LED光源模组，补偿转向时的可视区域30°，增加司机在30千米车速时小半径转弯时，左右两边的可视区域各增加30°。
3.4车速20千米/小时，15米小半径转弯路况下的可视区域补光
根据JTG B01-2014，要求在车速为20千米/小时，最小转弯半径为30米，最小停车视距为15米，此时在安全可靠的停车视距内，车身转向了42°。如图8所示，此时车身前照灯随动控制系统分别增加点亮转向光源12中的所有LED光源模组，补偿转向时的可视区域42°，增加司机在20千米车速时极小半径转弯时，左右两边的可视区域各增加42°。
当左转弯时，车身总控MCU的随动自适应控制系统自动获取车身的 速度传感器，方向盘转角感应器以及车身横摆角速度转角感应器的综合数据，并以这些数据计算出汽车的转弯半径以及所需要的车侧面的照度区域宽度值，并输出对应的驱动指令给LED车灯的驱动模块，按最佳适配性来依次打开转向光源12附加的4个独立LED光源模组以扩宽司机在左转弯时左边可见区域和光照强度。
4、雨雪天气或雾霾天气的亮度自适应，
雨雪天气或雾霾天气时，车身的光照强度应器的信号通过控制器传给车身总控MCU，身总控MCU的控制程序控制LED光源模组阵列1的驱动电路的输出电流，从而通过增加每个LED光源模组的驱动功率来加强前照灯的亮度和照度，以提高汽车在恶劣的雨雪和雾霾天气下行驶时的可见性和可视区域。
5、加速或减速，重载，爬坡和城市道路行驶的自适应系统
汽车加速，减速，重载，爬坡和城市道路行驶中的自适应系统的各个感应器的数值经过MCU控制系统的综合比较算法最终分别输出驱动信号给个执行单元，由远近光LED光源的智能点亮驱动系统和整灯的多个独立远近光源，以及上下两组偏射的辅助补光光源来改善整个大前灯的横向光形宽度，以及车灯整体向下或向上照射距离和高度，以达到最佳安全驾驶照明的舒适要求。车身加速或减速时，车身速度感应器的数据传输给车身总控MCU，由车身总控系统来选择点亮大前灯的上下偏振辅助光源模块会增加大前灯的照亮区域向上或向下扩展，以提高司机行车时可视区域的最佳匹配。通过光学镜面的反射原理，LED光源发出的光线经过反光杯的镜面的反射，使得出光角度的分布区域与地平面的成6～10独的角度，来自动补偿汽车在减速，重载或爬坡时的光照区域。通过光学镜面的反射原理，LED光源发出的光线经过反光杯的镜面的反射，使得出光角度的分布区域与地平面的成6～10独的角度，来自动补偿汽车在价速，下坡时的光照区域。
6、城市道路，乡村道路和高速公路上的自适应随动大前灯照明：
当汽车行驶在不同的公路环境中时，根据车身环境传感器的比较数据，由车身总控MCU的综合控制模块来分别优化组合驱动左右前照灯的14个独立LED光源模组以及左右两个前照灯的上下偏振补光单元，以输出最佳的自适应的随动可视驾驶区域，提高行车的安全性和舒服性。

Claims (10)

  1. 一种自适应远近光一体LED多模组前照灯，其特征在于：包括远近光随动自适应光型控制系统、补偿光系统和色温控制系统；
    所述远近光随动自适应光型控制系统包括LED光源模组阵列，所述LED光源模组阵列包括若干LED光源模组，其中包括两个以上相互平行设置且光轴与车身中心平行的LED光源模组形成直行光源，包括一个以上设置在直行光源外侧且光轴与车身中心呈锐角夹角的LED光源模组形成转向光源，转向光源中的LED光源模组的光轴与车身中心之间的夹角从内往外依次增大；直行光源比转向光源靠近车身中心；当车辆正常行驶时，直行光源点亮；当车辆夜间会车时，关闭直行光源中的一个或多个LED光源模组以减弱直行光源光照强度；当车辆夜间转弯时，点亮转向光源中的一个或多个LED光源模组；所述LED光源模组包括第一LED光源、与第一LED光源配合的第一曲面反射器、第二LED光源、与第二LED光源配合的第二曲面反射器和凸透镜，单独点亮第一LED光源时，LED光源模组打出近光光型，当第一LED光源和第二LED光源同时点亮时，LED光源模组打出远光光型；
    所述补偿光系统包括若干位于远近光随动自适应光型控制系统上方的上偏光辅助补光单元和若干位于远近光随动自适应光型控制系统下方的下偏光辅助补光单元；所述上偏光辅助补光单元包括上偏光LED光源和上偏光反光面，上偏光LED光源位于上偏光反光面的底部，上偏光LED光源发出的光线经过上偏光反光面的反射，使得出光角度的分布区域与地平面的成6～10°，来自动补偿车辆在减速、重载或爬坡时的光照区域；所述下偏光辅助补光单元包括下偏光LED光源和下偏光反光面，下偏光LED光源位于下偏光反光面的顶部，下偏光LED光源发出的光线经过下偏光反光面的反射，使得出光角度的分布区域与地平面的成6～10°，来自动补偿车辆在减速和下坡时的光照区域。
  2. 根据权利要求1所述的一种自适应远近光一体LED多模组前照灯，其特征在于：所述第一LED光源和第二LED光源均包括LED芯片、线路板和散热器，所述线路板安装在散热器上，所述线路板的中间镂空，所述散热器上对应线路板镂空处形成安装平面，所述LED芯片固定在所述安装平面上；所述线路板表面设有焊盘，所述LED芯片通过金线与焊盘连接；线路板的镂空处与安装平面形成凹槽，所述凹槽内填充有荧光硅胶。
  3. 根据权利要求2所述的一种自适应远近光一体LED多模组前照灯， 其特征在于：第一LED光源和第二LED光源的制造方法包括以下步骤：
    (1)在散热器的顶部预加工出一个安装平面；
    (2)将线路板中间镂空并贴合在散热器上，镂空处与预加工出的安装平面对应；
    (3)在线路板的表面设置焊盘，焊盘采用表面沉金处理；
    (4)将若干LED芯片按串并方式置于线路板中间镂空区域处的散热器安装平面上，粘接LED芯片的粘接剂使用导热系数25W/m*k的银胶；
    (5)将LED芯片串并线路的正负极与线路板上的焊盘连接；
    (6)将高反射有机胶沿线路板注胶孔灌入镂空处，使LED芯片周围至线路板镂空周围区域全面覆盖，灌胶量不超出LED芯片表面，加热使胶体固化；
    (7)将荧光粉硅胶的混合物灌封LED芯片和金线；
    (8)加温固化LED封装胶。
  4. 根据权利要求1所述的一种自适应远近光一体LED多模组前照灯，其特征在于：所述第一曲面反射器的设计方法包括以下步骤：
    (1)划分LED光源立体角：将LED设为坐标原点，α为出射光线与X轴组成的平面与XOZ平面的夹角，β为出射光线与X轴的夹角；对光源的立体角进行均匀离散化，把α等分成i份，对于每一个α，都将β等分成j份，得到α(i)和β(i,j)的数组；
    (2)划分接收面网格：根据配光要求，对应于光源立体角的划分，接收面的直角坐标也相应的在x方向上分成i份，对于每一份x，都将y方向分成j份，在接收面直角坐标系中得到与光源立体角中α(i)和β(i,j)数组一一对应的x(i)和y(i,j)数组；
    (3)计算自由曲面上离散点的坐标：设给定的光源的光通量为Q，因为使用的LED光源为朗伯源，其光强分布为中心光强的余弦分布，朗伯光源的中心光强为I0，由与光源中心轴夹角为α1与光源中心轴夹角为α2的入射光线之间的能量可以表示为：
    Figure PCTCN2016089990-appb-100001
    每一小份立体角内的光通量为：
    Figure PCTCN2016089990-appb-100002
    由于每一小份立体角内的取值是已知的，那么根据公式(1)，(2)计算出中心光强I0和每一小份立体角内的能量值大小；
    在目标照明区域水平线下的部分，每一份α角所对应的是一个长为y(i,j+1)-y(i,j)，宽为x(i+1)-x(i)的矩形区域，每个矩形区域的总能量为：
    Etotal1＝Ec·[x(i+1)-x(i)]·[y(i,j+1)-y(i,j)]  (3)
    式中，Ec表示照度值，由于区域Ⅰ、Ⅱ、Ⅲ、Ⅳ区域的照度值各不相同，故预设照度E，照度控制因子γ，对于不同区域有：
    Ec＝E·γ(k)  k＝1,2,3,4  (4)
    其中0≤γ(k)≤1，k的取值与Ⅰ、Ⅱ、Ⅲ、Ⅳ区域一一对应，且γ(k)值各不相同，需根据模拟结果在计算中不断调整以达到标准的要求；
    在目标照明区域水平线上的部分，划分时存在三角形区域，其高为y(i,j+1)-y(i,j)，底边为x(i+1)-x(i)，该区域的总能量为：
    Figure PCTCN2016089990-appb-100003
    在不考虑能量的损耗的情况下，LED光源发出的能量等于接收面上接收到的能量，由能量守恒定律可得：
    Energy＝Etotal1+Etotal2  (6)
    假设光线在与反射器作用时发生全反射，由折反射定律可得到自由曲面上点的法向量，利用这个法向量求得切平面，通过求切平面与入射光线的交点得到曲线上下一点的坐标。折反射定律的矢量形式可表示为：
    Figure PCTCN2016089990-appb-100004
    其中n为折射率，这里n取值为1，
    Figure PCTCN2016089990-appb-100005
    为入射光线单位向量、出射光线单位向量、单位法向量；
    在迭代计算时，首先需要确定一个计算的起始点，由这个初始点算出一条边界曲线，再由边界曲线的上的每一个点为初始点计算出整个自由曲面。
  5. 根据权利要求1所述的一种自适应远近光一体LED多模组前照灯，其特征在于：所述第二曲面反射器的设计方法包括以下步骤：
    (1)划分接收面网格：远光照度要求，中心处应具有较高亮度，并向周围逐渐减弱，将接收面的直角坐标也相应的在x方向上分成i份，对于每一份x，都将y方向分成j份，在接收面直角坐标系中得到与光源立体角中α(i)和β(i,j)数组一一对应的x(i)和y(i,j)数组；
    (2)照度控制因子设置：由于远光要求中心照度高，并向周围逐渐减弱，所以所划分网格环线设置照度控制因子，对于不同环线有：
    Ec＝E·γ(k)  k＝1,2,3,4；
    (3)计算自由曲面上离散点的坐标：设给定的光源的光通量为Q，因为使用的LED光源为朗伯源，其光强分布为中心光强的余弦分布，朗伯光源的中心光强为I0，由与光源中心轴夹角为α1与光源中心轴夹角为α2的入射光线之间的能量可以表示为：
    Figure PCTCN2016089990-appb-100006
    每一小份立体角内的光通量为：
    Figure PCTCN2016089990-appb-100007
    由于每一小份立体角内的取值是已知的，那么根据公式(1)，(2)计算出中心光强I0和每一小份立体角内的能量值大小；
    在目标照明区域水平线下的部分，每一份α角所对应的是一个长为y(i,j+1)-y(i,j)，宽为x(i+1)-x(i)的矩形区域，每个矩形区域的总能量为：
    Etotal1＝Ec·[x(i+1)-x(i)]·[y(i,j+1)-y(i,j)]  (3)
    式中，Ec表示照度值，由于区域Ⅰ、Ⅱ、Ⅲ、Ⅳ区域的照度值各不相同，
    其中0≤γ(k)≤1，k的取值与Ⅰ、Ⅱ、Ⅲ、Ⅳ区域一一对应，且γ(k)值各不相同，需根据模拟结果在计算中不断调整以达到标准的要求；
    在目标照明区域水平线上的部分，划分时存在三角形区域，其高为y(i,j+1)-y(i,j)，底边为x(i+1)-x(i)，该区域的总能量为：
    Figure PCTCN2016089990-appb-100008
    在不考虑能量的损耗的情况下，LED光源发出的能量等于接收面上接收到的能量，由能量守恒定律可得：
    Energy＝Etotal1+Etotal2  (6)
    假设光线在与反射器作用时发生全反射，由折反射定律可得到自由曲面上点的法向量，利用这个法向量求得切平面，通过求切平面与入射光线的交点得到曲线上下一点的坐标。折反射定律的矢量形式可表示为：
    Figure PCTCN2016089990-appb-100009
    其中n为折射率，这里n取值为1，
    Figure PCTCN2016089990-appb-100010
    为入射光线单位向量、出射光线单位向量、单位法向量；
    在迭代计算时，首先需要确定一个计算的起始点，由这个初始点算出一条边界曲线，再由边界曲线的上的每一个点为初始点计算出整个自由曲面。
  6. 根据权利要求4或5所述的一种自适应远近光一体LED多模组前照 灯，其特征在于：得出的自由曲面的模型建立方法：通过前面所述设计方法，迭代计算出自由曲面反射器的离散坐标点，将些离散点保存为文本文件并导入三维制图软件SolidWorks中，拟合成为平滑的曲面，得到反射器的实体模型，并将其导入光学仿真软Lucidshape中，设置好透镜的材料属性、光源的属性以及接收面的属性，对所得的模型进行光线追迹。
  7. 根据权利要求1所述的一种自适应远近光一体LED多模组前照灯，其特征在于：所述LED光源模组阵列一共设有七个LED光源模组，其中三个LED光源模组为直行光源，四个LED光源模组为转向光源。
  8. 根据权利要求7所述的一种自适应远近光一体LED多模组前照灯，其特征在于：所述转向光源的四个LED光源模组中，从内往外依次与车身中心线的夹角为13～17°、17～21°、28～32°和40～44°。
  9. 根据权利要求1所述的一种自适应远近光一体LED多模组前照灯，其特征在于：色温控制系统包括若干前雾灯LED光源，所述前雾灯LED光源包括色温为2700K的LED、色温为7000K的LED和雾灯反光杯。
  10. 根据权利要求1所述的一种自适应远近光一体LED多模组前照灯，其特征在于：前照灯还包括闭环自适应随动控制系统，其包括车身感应器组、车身总控MCU和前照灯AFS分系统AU，车身感应器组与车身总控MCU连接，车身总控MCU通过前照灯AFS分系统AU控制远近光随动自适应光型控制系统、补偿光系统和色温控制系统；所述车身感应器组包括车身速度感应器、车身倾角/转角感应器、车身重载感应器、车身路况震动感应器、方向盘转角感应器、下雨量感应器、雾霾/下雪感应器和闹市环境感应器。
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