CN102901043A - Optical lens with free-form surfaces for LED dipped headlight of motorcycle - Google Patents
- ️Wed Jan 30 2013
CN102901043A - Optical lens with free-form surfaces for LED dipped headlight of motorcycle - Google Patents
Optical lens with free-form surfaces for LED dipped headlight of motorcycle Download PDFInfo
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Abstract
本发明公开了用于LED摩托车近光灯的自由曲面光学透镜，所述透镜的内侧是一具有空腔，使用时LED从该开口端进入并安装于该空腔内；透镜包括入射面及出射面，透镜的内侧为所述入射面，入射面由所述空腔顶部的自由曲面和腔壁的柱面构成；而透镜外侧的顶部平面即为所述出射面，透镜外侧的侧面为外围自由曲面；所述透镜分为上、下两部分，透镜上部分主要用于将LED光源射向水平面以上的光照向水平面以下的照明面上；透镜下部分则主要用于将LED光源向水平面以下扩散的光会聚到水平面以下的照明面上。本发明结构简单，体积小，不需要其它的辅助装置进行配光，提高了光能利用率，眩光效应低，达到GB5948-1998的配光要求。
The invention discloses a free-form optical lens used for low beams of LED motorcycles. The inner side of the lens is a cavity, and the LED enters from the opening end and is installed in the cavity when in use; the lens includes an incident surface and The exit surface, the inner side of the lens is the incident surface, and the incident surface is composed of the free-form surface at the top of the cavity and the cylindrical surface of the cavity wall; the top plane outside the lens is the exit surface, and the side surface outside the lens is the periphery Free-form surface; the lens is divided into upper and lower parts, the upper part of the lens is mainly used to direct the light from the LED light source above the horizontal plane to the lighting surface below the horizontal plane; the lower part of the lens is mainly used to direct the LED light source to the lighting surface below the horizontal plane The diffused light converges onto the lighting surface below the water level. The invention has simple structure and small volume, does not need other auxiliary devices for light distribution, improves light energy utilization rate, has low glare effect, and meets the light distribution requirements of GB5948-1998.
Description
技术领域 technical field
本发明涉及LED摩托车灯照明技术领域，特别涉及用于LED摩托车近光灯的自由曲面光学透镜。The invention relates to the technical field of LED motorcycle lamp lighting, in particular to a free-form surface optical lens used for LED motorcycle low beam lamps.
背景技术 Background technique
发光二极管（LED）具有体积小、能耗低、响应快、寿命长等诸多优点，近年来在照明领域中被广泛的应用，在车用照明中的应用也越来越普遍。但是，由于LED发光特性不同于传统光源，为了满足配光标准，提高系统性能，需针对LED来进行二次光学设计，从而实现前照灯照明系统的最优化。Light-emitting diodes (LEDs) have many advantages such as small size, low energy consumption, fast response, and long life. In recent years, they have been widely used in the field of lighting, and their applications in automotive lighting are becoming more and more common. However, since the luminous characteristics of LEDs are different from traditional light sources, in order to meet the light distribution standards and improve system performance, it is necessary to carry out secondary optical design for LEDs, so as to realize the optimization of the headlight lighting system.
对于道路安全来说，摩托车前照灯的性能尤其重要，在设计上，国家标准GB5948-1998对摩托车前照灯的配光要求做了规定。对于近光灯，国标要求在车灯前25m远的照明面上产生一水平线和水平线右侧向上15°的明暗截止线，且照明面上不同区域的照度值大小也做了相应的规定。For road safety, the performance of motorcycle headlights is particularly important. In terms of design, the national standard GB5948-1998 stipulates the light distribution requirements of motorcycle headlights. For dipped beams, the national standard requires a horizontal line and a cut-off line of 15° upward on the right side of the horizontal line to be formed on the lighting surface 25m away from the headlights, and the illuminance values of different areas on the lighting surface are also regulated accordingly.
发明内容 Contents of the invention
针对LED摩托车前照灯设计面临的主要问题，本发明提供了用于LED摩托车近光灯的自由曲面光学透镜，该透镜制作安装方便，体积小，眩光效应低，光能利用率高，并能产生满足国标GB5948-1998的配光要求的照度分布。本发明运用旋转轴对称LED照明系统的设计方法，有效地减小了自由曲面仿真建模时产生的误差，同时也很好地提高了透镜的光学精度和工作效率。Aiming at the main problems faced by the design of LED motorcycle headlights, the invention provides a free-form optical lens for LED motorcycle low beams. The lens is easy to manufacture and install, small in size, low in glare effect, and high in light energy utilization. And can produce the illuminance distribution that meets the light distribution requirements of the national standard GB5948-1998. The invention uses the design method of the rotational axis symmetric LED lighting system to effectively reduce the errors generated during simulation modeling of the free-form surface, and at the same time improve the optical precision and work efficiency of the lens.
本发明采用如下技术方案：The present invention adopts following technical scheme:
用于LED摩托车近光灯的自由曲面光学透镜，所述透镜的内侧是一具有空腔，与空腔顶部正对的是开口端，使用时LED从该开口端进入并安装于该空腔内；透镜包括入射面及出射面，透镜的内侧为所述入射面，入射面由所述空腔顶部的自由曲面和腔壁的柱面构成；而透镜外侧的顶部平面即为所述出射面，透镜外侧的侧面为外围自由曲面；LED光源中心部分的光经过透镜时，在透镜内侧腔顶的所述自由曲面和透镜外侧的顶部平面出射面发生两次折射，再出射到照明面上；LED光源外围部分的光经过透镜时，先在透镜内侧腔壁的柱面进行折射，再在透镜外侧的外围自由曲面上发生全反射，接着又在透镜外侧的顶部平面出射产生折射，最后出射到照明面上；所述透镜分为上、下两部分，透镜上部分主要用于将LED光源射向水平面以上的光进行折射、反射和折射，然后照向水平面以下的照明面上；透镜下部分则主要用于将LED光源向水平面以下扩散的光进行折射、反射和折射，然后会聚到水平面以下的照明面上。A free-form optical lens used for LED motorcycle low-beam lights. The inner side of the lens is a cavity, and the top of the cavity is directly opposite to the open end. When in use, the LED enters from the open end and is installed in the cavity. Inside; the lens includes an incident surface and an outgoing surface, the inner side of the lens is the incident surface, and the incident surface is composed of the free-form surface at the top of the cavity and the cylindrical surface of the cavity wall; and the top plane outside the lens is the outgoing surface , the side outside the lens is a peripheral free-form surface; when the light in the central part of the LED light source passes through the lens, it is refracted twice on the free-form surface on the inner cavity top of the lens and the top plane exit surface outside the lens, and then emerges onto the lighting surface; When the light from the peripheral part of the LED light source passes through the lens, it is firstly refracted on the cylindrical surface of the inner cavity wall of the lens, then totally reflected on the outer peripheral free-form surface of the lens, and then refracted on the top plane outside the lens, and finally emitted to The lighting surface; the lens is divided into upper and lower parts, the upper part of the lens is mainly used to refract, reflect and refract the light above the horizontal plane from the LED light source, and then shine on the lighting surface below the horizontal plane; the lower part of the lens It is mainly used to refract, reflect and refract the light diffused by the LED light source below the horizontal plane, and then converge to the lighting surface below the horizontal plane.
进一步的，自由曲面透镜的形状确定如下：Further, the shape of the free-form surface lens is determined as follows:
以LED光源为坐标原点O建立坐标系，LED底面所在平面为XOY平面，过原点并与平面XOY垂直的轴为Z轴，其中平面XOZ为水平面。与Z轴交点为o（点O与点o间的距离为25m）且平行于平面XOY的平面为照明面，点o为照明面的中心点。首先根据摩托车前照灯近光灯在照明面上照度分布特征（如GB5948-1998），把照明面上的照明区域设定为以照明面的中心点为圆心，圆心左侧边线为水平线和圆心右侧边线为水平线向上15°斜线的部分圆形（即195°的扇形），然后对该部分圆形进行环带划分，再然后运用能量守恒定律对光源立体角进行划分，最后运用折反射定律通过数值计算即得到透镜的自由曲面。The coordinate system is established with the LED light source as the coordinate origin O, the plane where the bottom surface of the LED is located is the XOY plane, and the axis passing through the origin and perpendicular to the plane XOY is the Z axis, where the plane XOZ is the horizontal plane. The intersection point with the Z axis is o (the distance between point O and point o is 25m) and the plane parallel to the plane XOY is the lighting surface, and point o is the center point of the lighting surface. First, according to the illuminance distribution characteristics of motorcycle headlamp low beam on the lighting surface (such as GB5948-1998), the lighting area on the lighting surface is set as the center point of the lighting surface, and the left side of the circle center is the horizontal line and The sideline on the right side of the center of the circle is a part of the circle with a 15° slant upward from the horizontal line (that is, a 195° sector), and then divide the part of the circle into rings, and then use the law of energy conservation to divide the solid angle of the light source, and finally use the folding The law of reflection obtains the free-form surface of the lens through numerical calculation.
根据国标GB5948-1998，摩托车前照灯近光灯绝大部分的光照射在水平面以下的照明面上，仅在右侧存在与水平线向上成15°的照明区域。因此，所述透镜分为上、下两部分，透镜上部分主要将射向水平面以上的光进行折反射，然后照向水平面以下的照明面上；透镜下部分则主要将向水平面以下扩散的光进行折反射，然后会聚到水平面以下的照明面上。According to the national standard GB5948-1998, most of the light of the low beam of the motorcycle headlight is irradiated on the lighting surface below the horizontal plane, and there is only a lighting area at 15° upward from the horizontal line on the right side. Therefore, the lens is divided into an upper part and a lower part. The upper part of the lens mainly refracts and reflects the light above the horizontal plane, and then shines on the lighting surface below the horizontal plane; the lower part of the lens mainly reflects the light diffused below the horizontal plane. Refracts and then converges onto illuminated surfaces below the horizontal plane.
透镜的上部分和透镜的下部分的形状由如下确定：The shapes of the upper part of the lens and the lower part of the lens are determined by:
1、设定初始条件并对目标照明区域进行环带划分。1. Set the initial conditions and divide the target lighting area into rings.
首先目标照明面距LED的距离为d=25m，LED光源的总光通量为Q，中心光强为I0=Q/π。坐标系中θ为出射光线在XOY平面上的投影与X轴的夹角， 
对于近光灯，如前文所述设定其目标照明区域是部分圆形。For the low beam, set its target lighting area to be a partial circle as mentioned above.
对于透镜的上部分，设照明面上部分圆形的半径为rup；对照明面的坐标进行离散化，首先把圆半径rup等分成n份，ri表示等分后半径rup的第i份，其中0＜i≤n；然后同样以照明面中心点为圆心，分别以ri为半径画圆，将照明区域划分为部分圆形环带区域。在目标照明区域上，每一份部分圆形环带区域的能量为：For the upper part of the lens, let the radius of the partial circle on the illuminated surface be r up ; to discretize the coordinates of the illuminated surface, first divide the circle radius r up into n parts, and r i represents the second radius of r up after equal division i parts, where 0<i≤n; then also take the center point of the lighting surface as the center and draw circles with ri as the radius to divide the lighting area into partial circular ring areas. On the target lighting area, the energy of each part of the circular ring area is:
式中，Eu·ki表示照度值，根据国标要求，故设置常量Eu为预设照度值，结合变量ki用来控制照明面上指定区域的照度值大小，用以形成预定的照度分布，其中，0≤ki≤1。ki的取值大小需根据照明面上照度要求设定，如对于最亮区域ki的取值范围为0.9 - 1，对于边缘区域ki的取值范围为0 - 0.1。In the formula, E u k i represents the illuminance value. According to the requirements of the national standard, the constant E u is set as the preset illuminance value, and the variable k i is used to control the illuminance value of the specified area on the lighting surface to form a predetermined illuminance distribution, where 0≤k i ≤1. The value of ki needs to be set according to the illumination requirements on the lighting surface. For example, the value range of ki for the brightest area is 0.9 - 1, and the value range of ki for the edge area is 0 - 0.1.
另外，由于LED并非理想的点光源，但可以将LED视为近似点光源，因此对于透镜上部分的自由曲面，θ的取值范围不一定为0°- 195°，经过在计算中反复仿真模拟调整，θ的取值范围可以取-4°- 202°，就能在照明面上产生Y轴左侧为水平线和Y轴右侧为水平线向上15°的明暗截止线。In addition, since the LED is not an ideal point light source, but the LED can be regarded as an approximate point light source, the value range of θ is not necessarily 0°-195° for the free-form surface on the upper part of the lens. After repeated simulations in the calculation Adjustment, the value range of θ can be -4°-202°, which can produce a light and dark cut-off line on the lighting surface where the left side of the Y axis is the horizontal line and the right side of the Y axis is the horizontal line 15° upward.
那么，对于透镜的下部分，θ的取值范围就为202°- 356°。Then, for the lower part of the lens, the value range of θ is 202°-356°.
同理，对于透镜的下部分，设照明面上的部分圆形的半径为rdown。对照明面的坐标进行离散化，即把圆半径rdown等分成m份，rj表示等分后半径rdown的第j份，其中，0＜j≤m，最后将照明区域划分为部分圆形环带区域。在目标照明区域上，每一份部分圆形环带区域的能量为：Similarly, for the lower part of the lens, let the radius of the partial circle on the illuminating surface be r down . Discretize the coordinates of the lighting surface, that is, divide the radius r down of the circle into m parts, and r j represents the jth part of the radius r down after equal division, where 0<j≤m, and finally divide the lighting area into partial circles ring zone. On the target lighting area, the energy of each part of the circular ring area is:
式中，常量Ed为预设照度值，变量kj为照度控制参数。Ed和kj的取值与上文所述的Eu和ki同理。In the formula, the constant E d is the preset illuminance value, and the variable k j is the illuminance control parameter. The values of E d and k j are the same as E u and k i mentioned above.
需要注意的是，透镜的尺寸与照明面的位置、照明区域的半径以及透镜内侧空腔的口径有关。此处，为了使透镜上、下两部分美观协调，具有整体性，可以采取透镜上部分的照明区域半径大于透镜下部分的照明区域半径，或者增大透镜上部分的空腔口径。It should be noted that the size of the lens is related to the position of the illuminating surface, the radius of the illuminating area and the aperture of the cavity inside the lens. Here, in order to make the upper and lower parts of the lens aesthetically coordinated and integrated, the radius of the illuminated area of the upper part of the lens can be larger than that of the lower part of the lens, or the cavity diameter of the upper part of the lens can be increased.
2、利用能量守恒定律将光源立体角进行划分。2. Use the law of conservation of energy to divide the solid angle of the light source.
对应于目标照明区域的环带划分，将光源的立体角进行离散化。The solid angle of the light source is discretized corresponding to the annulus division of the target lighting area.
对于透镜的上部分，将光源中心部分的立体角进行离散化（此例中设置为 
对于透镜的上部分，在光线射入透镜之前，光源中心部分的每一份角度内光源的光通量Euc和光源外围部分的每一份角度内光源的光通量Eul的总光通量为：For the upper part of the lens, before the light enters the lens, the total luminous flux of the luminous flux E uc of the light source in each angle of the central part of the light source and the luminous flux E ul of the light source in each angle of the peripheral part of the light source is:
如前文所述，上式θ的取值范围都为-4°- 202°。那么，不考虑光在通过透镜和传播过程中的能量损失，根据能量守恒有：As mentioned above, the value range of the above formula θ is -4°-202°. Then, regardless of the energy loss of light passing through the lens and propagating, according to energy conservation:
Eup=Euc+Eul E up =E uc +E ul
联合上述各式，从而可以求解得到对应的 
同理，对于透镜的下部分，将光源中心部分的立体角进行离散化（此例中 
其中，θ的取值范围为202°- 356°。不考虑光在通过透镜和传播过程中的能量损失，根据能量守恒有：Among them, the value range of θ is 202°-356°. Regardless of the energy loss of light in the process of passing through the lens and propagating, according to energy conservation:
Edown=Edc+Edl E down =E dc +E dl
联合上述各式，也可以求解得到对应的和 
3、由折反射定律求出自由曲面上的点坐标3. Calculate the point coordinates on the free-form surface by the law of refraction and reflection
由折反射定律求出所述曲面上点的法向量，利用这个法向量求得切线，通过求切线与入射光线的交点得到曲线上点的坐标，折反射定律的矢量形式可表示为：The normal vector of the point on the surface is obtained by the law of refraction, the tangent is obtained by using this normal vector, and the coordinates of the point on the curve are obtained by obtaining the intersection point of the tangent and the incident light. The vector form of the law of refraction can be expressed as:
其中， 
对于透镜的上部分，我们先计算透镜的中心部分，首先需要确定的是透镜的计算初始点，初始点的确定如下：先设初始点的 
接着计算透镜的外围部分，同样在XOZ平面上，过第一自由曲线的最后一个点作与Y轴垂直的第二直线，第二直线与 内侧空腔的口径大小，此点对应的值为90°，该第二直线表示的是透镜上部分内侧腔壁的柱面。透镜外围部分自由曲面初始点的 
同理，对于透镜的下部分，根据上面已选定的透镜腔顶自由曲面高度和透镜厚度，可以计算得到透镜中心部分的第三自由曲线和第三直线，第三自由曲线表示的是透镜下部分内侧空腔顶部的自由曲面，第三直线表示的是透镜下部分外侧顶部的平面（其实第三直线等价于第一直线1，即我们将透镜上、下两部分的出射面设置为同一平面）。接着再求得透镜外围部分的第使直线和第四自由曲线，第使直线表示的是透镜下部分内侧腔壁的柱面，第四自由曲线表示的是透镜下部分外侧外围的自由曲面。Similarly, for the lower part of the lens, the third free curve and the third straight line of the central part of the lens can be calculated according to the height of the free-form surface on the top of the lens cavity and the thickness of the lens selected above. The third free curve represents the lower part of the lens. Part of the free-form surface on the top of the inner cavity, the third straight line represents the plane on the outer top of the lower part of the lens (in fact, the third straight line is equivalent to the first straight line 1, that is, we set the exit surfaces of the upper and lower parts of the lens as same plane). Then obtain the first straight line and the fourth free curve of the peripheral part of the lens, the first straight line represents the cylinder of the inner cavity wall of the lower part of the lens, and the fourth free curve represents the free curved surface of the outer periphery of the lower part of the lens.
正如前文所述，为了使透镜上、下两部分美观协调，具有整体性，可以采取透镜上部分的空腔口径大于透镜下部分的空腔口径。As mentioned above, in order to make the upper and lower parts of the lens look harmonious and integrated, the cavity diameter of the upper part of the lens may be larger than the cavity diameter of the lower part of the lens.
4、利用机械仿真软件将得到的点拟合为曲面4. Use mechanical simulation software to fit the obtained points into a curved surface
将得到的透镜上、下两部分的离散点坐标分别导入到机械建模软件，拟合成八条位于YOZ平面上的线段，其中四条为直线，四条为自由曲线。在线与线的交接处做适当的处理和相应的连接，使透镜上部分的四条线段合为一条连续的分段曲线，然后使该曲线绕Z轴正方向旋转94°，再绕Z轴负方向旋转112°（即θ取-4°- 202°），即可加工成透镜上部分的实体模型。同理，使透镜下部分的四条线段合为一条连续的分段曲线，然后使该曲线绕Z轴正方向旋转68°，再绕Z轴负方向旋转86°（即θ取202°- 356°），即可加工成透镜下部分的实体模型。通过对透镜上、下两部分进行加工拟合，最终得到LED摩托车近光灯的自由曲面光学透镜模型。Import the obtained discrete point coordinates of the upper and lower parts of the lens into the mechanical modeling software, and fit them into eight line segments on the YOZ plane, four of which are straight lines and four are free curves. Proper processing and corresponding connections are made at the intersection of lines and lines, so that the four line segments on the upper part of the lens are combined into a continuous segmented curve, and then the curve is rotated 94° around the positive direction of the Z-axis, and then around the negative direction of the Z-axis Rotate 112° (that is, θ takes -4°-202°), and it can be processed into a solid model of the upper part of the lens. In the same way, the four line segments in the lower part of the lens are combined into a continuous segmented curve, and then the curve is rotated 68° around the positive direction of the Z axis, and then rotated 86° around the negative direction of the Z axis (that is, θ is 202°-356° ), which can be processed into a solid model of the lower part of the lens. By processing and fitting the upper and lower parts of the lens, the free-form surface optical lens model of the LED motorcycle low beam light is finally obtained.
与现有技术相比，本发明的优点有：LED光源发出的光能量仅经自由曲面透镜折反射后出射，不需要其它的辅助装置进行配光，减少了配光系统对光能的损耗，提高了光能利用率。透镜的体积小，眩光效应低，达到GB5948-1998的配光要求，且透镜的外形设计便于散热装置和LED光源的安装，有利于提高整个灯具的散热效率。本发明利用旋转轴对称LED照明系统设计方法，不仅便于仿真建模，而且所建模型的光学精度高。Compared with the prior art, the present invention has the following advantages: the light energy emitted by the LED light source is only refracted and reflected by the free-form surface lens, and no other auxiliary devices are needed for light distribution, which reduces the loss of light energy by the light distribution system. The utilization rate of light energy is improved. The size of the lens is small, the glare effect is low, and it meets the light distribution requirements of GB5948-1998, and the shape design of the lens is convenient for the installation of the heat sink and the LED light source, which is conducive to improving the heat dissipation efficiency of the entire lamp. The invention utilizes the design method of the rotational axis symmetrical LED lighting system, which is not only convenient for simulation modeling, but also has high optical precision of the built model.
附图说明 Description of drawings
图1为实施方式中照明面上目标区域环带划分示意图。Fig. 1 is a schematic diagram of division of a target area on an illumination surface in an embodiment.
图2为实施方式中照明系统坐标系示意图。Fig. 2 is a schematic diagram of the coordinate system of the lighting system in the embodiment.
图3为实施方式中光线经过透镜配光的示意图。Fig. 3 is a schematic diagram of light distribution through a lens in an embodiment.
图4为实施方式中近光灯透镜上部分的三维立体正视示意图。Fig. 4 is a schematic three-dimensional front view of the upper part of the low beam lens in the embodiment.
图5为实施方式中近光灯透镜上部分的二维正视示意图。Fig. 5 is a schematic two-dimensional front view of the upper part of the low beam lens in the embodiment.
图6为实施方式中近光灯透镜上部分的三维立体侧视示意图。Fig. 6 is a schematic three-dimensional side view of the upper part of the low beam lens in the embodiment.
图7为实施方式中近光灯透镜下部分的三维立体正视示意图。Fig. 7 is a schematic three-dimensional front view of the lower part of the low beam lens in the embodiment.
图8为实施方式中近光灯透镜下部分的二维正视示意图。Fig. 8 is a schematic two-dimensional front view of the lower part of the low beam lens in the embodiment.
图9为实施方式中近光灯透镜下部分的三维立体侧视示意图。Fig. 9 is a schematic three-dimensional side view of the lower part of the low beam lens in the embodiment.
图10为实施方式中近光灯透镜的三维立体侧视示意图。Fig. 10 is a schematic three-dimensional side view of a low beam lens in an embodiment.
图11为实施方式中近光灯透镜的三维立体仰视示意图。Fig. 11 is a schematic three-dimensional bottom view of the low beam lens in the embodiment.
图12为实施方式中近光灯透镜的三维立体后视示意图。Fig. 12 is a schematic three-dimensional rear view of the low beam lens in the embodiment.
具体实施方式 Detailed ways
以上内容已经对本发明作了充分的说明，以下结合附图和具体实施方式对本发明作进一步详细的说明。The above content has fully described the present invention, and the present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.
本发明公开LED摩托车灯近光灯光学透镜，该透镜体积小，眩光效应低，光能利用率高，安装方便，能产生满足国标GB5948-1998的配光要求的光型和照度分布。The invention discloses a low-beam light optical lens for LED motorcycle lights. The lens has small volume, low glare effect, high light energy utilization rate, convenient installation, and can produce light patterns and illuminance distributions meeting the light distribution requirements of the national standard GB5948-1998.
本实例中用于LED摩托车近光灯的自由曲面光学透镜由透明材料制成，透明材料可为PMMA或PC或光学玻璃。所述透镜的内侧是一空腔，照明时需将LED安装于该空腔内。透镜包括入射面及出射面。透镜的内侧是入射面，即入射面由空腔顶部的自由曲面和腔壁的柱面构成；而透镜外侧的顶部平面即出射面。LED光源中心部分的光经过透镜时，在透镜内侧腔顶的自由曲面入射面和透镜外侧顶部的平面出射面发生两次折射，再出射到照明面上；LED光源外围部分的光经过透镜时，先在透镜内侧腔壁的柱面入射面进行折射，再在透镜外侧外围的自由曲面上发生全反射，接着又在透镜外侧顶部的平面出射面产生折射，最后出射到照明面上。In this example, the free-form optical lens used for the low beam of the LED motorcycle is made of transparent material, and the transparent material can be PMMA or PC or optical glass. The inner side of the lens is a cavity, and the LED needs to be installed in the cavity when illuminating. The lens includes an incident surface and an outgoing surface. The inside of the lens is the incident surface, that is, the incident surface is composed of the free-form surface at the top of the cavity and the cylindrical surface of the cavity wall; and the top plane outside the lens is the exit surface. When the light in the central part of the LED light source passes through the lens, it refracts twice on the incident surface of the free-form surface on the inner cavity top of the lens and the plane exit surface on the outer top of the lens, and then exits to the lighting surface; when the light in the peripheral part of the LED light source passes through the lens, Refraction occurs on the cylindrical incident surface of the inner cavity wall of the lens first, then total reflection occurs on the free-form surface of the outer periphery of the lens, and then refraction occurs on the plane exit surface of the outer top of the lens, and finally exits to the lighting surface.
对于近光灯，国标要求在车灯前25m远的照明面上产生一左侧为水平线和右侧为水平线向上15°的明暗截止线，且照明面上不同区域的照度值大小也做了相应的规定。根据国标的配光要求的光型和照度分布，把照明面上的照明区域进行部分圆形环带划分，如图1所示。For low beams, the national standard requires that a light and dark cut-off line with the horizontal line on the left and the horizontal line on the right be 15° upward on the lighting surface 25m in front of the headlights, and the illuminance values of different areas on the lighting surface are also made correspondingly. Provisions. According to the light type and illuminance distribution required by the national standard for light distribution, the lighting area on the lighting surface is divided into partial circular rings, as shown in Figure 1.
然后运用能量守恒定律，对光源立体角进行划分，每一份立体角内的能量相对应于照明面上部分圆形环带的能量，如图2所示为照明系统坐标系示意图，以LED光源为坐标原点O建立坐标系，按照球坐标图示将LED光源立体角进行划分。坐标系中θ为出射光线在XOY平面上的投影与X轴的夹角， 
由于该光学系统关于Z轴旋转轴对称，因此可以考虑二维情况，以YOZ所在平面为例，透镜配光原理示意图如图3所示，LED光源中心部分的光经过透镜时，在透镜内侧腔顶的自由曲面入射面和透镜外侧顶部的平面出射面发生两次折射，再出射到照明面上；LED光源外围部分的光经过透镜时，先在透镜内侧腔壁的柱面入射面进行折射，再在透镜外侧外围的自由曲面上发生全反射，接着又在透镜外侧顶部的平面出射面产生折射，最后出射到照明面上。透镜的上部分主要将射向水平面以上的光折反射照向水平面以下的照明面上，透镜的下部分则主要将向水平面以下扩散的光折反射会聚到水平面以下的照明面上。在图3中，1和5分别为透镜上部分和下部分内侧腔顶的自由曲面，2和6分别为透镜上部分和下部分外侧顶部的平面，3和7分别为透镜上部分和下部分内侧腔壁的柱面，4和8为透镜上部分和下部分外侧外围的自由曲面，其中，1、2、5和6构成透镜的中心部分，3、4、7和8构成透镜的外围部分。Since the optical system is symmetrical about the Z-axis rotation axis, two-dimensional situations can be considered. Taking the plane where YOZ is located as an example, the schematic diagram of the lens light distribution principle is shown in Figure 3. The incident surface of the free-form surface of the top and the plane exit surface of the top outside the lens are refracted twice, and then emitted to the lighting surface; when the light from the peripheral part of the LED light source passes through the lens, it is first refracted on the cylindrical incident surface of the inner cavity wall of the lens, Then total reflection occurs on the free-form surface on the outer periphery of the lens, and then refraction occurs on the plane exit surface at the top of the outside of the lens, and finally exits to the lighting surface. The upper part of the lens mainly refracts and reflects the light incident above the horizontal plane to the illuminating surface below the horizontal plane, and the lower part of the lens mainly refracts and reflects the light diffused below the horizontal plane to the illuminating plane below the horizontal plane. In Figure 3, 1 and 5 are the free-form surfaces of the upper and lower inner cavity roofs of the lens, 2 and 6 are the planes of the outer top of the upper and lower parts of the lens, respectively, and 3 and 7 are the upper and lower parts of the lens, respectively. The cylindrical surface of the inner cavity wall, 4 and 8 are free curved surfaces on the outer periphery of the upper and lower parts of the lens, wherein 1, 2, 5 and 6 constitute the central part of the lens, and 3, 4, 7 and 8 constitute the peripheral part of the lens .
对于透镜的上部分，根据设定的初始条件、目标照明区域划分的环带分布以及相应的通过能量守恒定律进行划分的光源立体角，运用折反射定律求出入射光线所作用在自由曲面上的法向量利用这个法向量求得切线，通过求切线与入射光线的交点得到所求线段上点的坐标。由这一系列计算出来的点可以拟合出四条位于XOZ平面上的线段，其中两条为直线，两条为自由曲线。然后在线与线的交接处做适当的处理和相应的连接，使这四条线段合为一条连续的分段曲线，然后使该曲线绕Z轴正方向（顺时针）旋转94°，再绕Z轴负方向（逆时针）旋转112°，即可加工成透镜上部分的实体模型。如图4所示，其中，虚线表示的曲线9为透镜上部分在YOZ平面上的自由曲线。图5和图6所示为分别透镜上部分的三维立体正视示意图和三维立体侧视示意图。For the upper part of the lens, according to the set initial conditions, the annulus distribution of the target lighting area division and the corresponding solid angle of the light source divided by the law of energy conservation, the law of refraction and reflection is used to obtain the incident light acting on the free-form surface The normal vector uses this normal vector to obtain the tangent, and obtains the coordinates of the point on the desired line segment by finding the intersection of the tangent and the incident ray. The points calculated from this series can fit four line segments on the XOZ plane, two of which are straight lines and two are free curves. Then do appropriate processing and corresponding connection at the junction of the line and the line, so that the four line segments are combined into a continuous segmented curve, and then rotate the curve 94° around the positive direction of the Z axis (clockwise), and then around the Z axis Rotate 112° in the negative direction (counterclockwise), and it can be processed into a solid model of the upper part of the lens. As shown in FIG. 4 , the curve 9 indicated by the dotted line is a free curve of the upper part of the lens on the YOZ plane. FIG. 5 and FIG. 6 are respectively a three-dimensional stereoscopic front view diagram and a three-dimensional stereoscopic side view schematic diagram of the upper part of the lens.
同理，对于透镜的下部分，根据设定的初始条件、目标照明区域划分的环带分布以及相应的通过能量守恒定律进行划分的光源立体角，运用折反射定律也可求出在YOZ平面上的四条线段。将这四条线段合为一条连续的分段曲线，然后使该曲线绕Z轴正方向（顺时针）旋转68°，再绕Z轴负方向（逆时针）旋转86°，即可加工成透镜下部分的实体模型。如图7所示，其中，虚线表示的曲线10为透镜下部分在YOZ平面上的自由曲线。图8和图9所示分别为透镜下部分的三维立体正视示意图和三维立体侧视示意图。Similarly, for the lower part of the lens, according to the set initial conditions, the annulus distribution of the target lighting area division and the corresponding solid angle of the light source divided by the law of energy conservation, the law of refraction and reflection can also be used to obtain the YOZ plane of the four line segments. Combine these four line segments into a continuous segmented curve, then rotate the curve 68° around the positive direction of the Z-axis (clockwise), and then rotate 86° around the negative direction of the Z-axis (counterclockwise), then it can be processed into a lens under the lens Partial mockup. As shown in FIG. 7 , the curve 10 indicated by the dotted line is a free curve of the lower part of the lens on the YOZ plane. FIG. 8 and FIG. 9 are respectively a three-dimensional front view and a three-dimensional side view of the lower part of the lens.
最后，为了使透镜上、下两部分美观协调，具有整体性，通过对透镜上、下两部分进行加工拟合，最终得到LED摩托车近光灯的自由曲面光学透镜模型。如图8、图9和图10所示，分别为近光灯透镜的三维立体侧视示意图、仰视示意图和后视示意图。Finally, in order to make the upper and lower parts of the lens beautiful and harmonious, and have integrity, the free-form surface optical lens model of the LED motorcycle low beam light is finally obtained by processing and fitting the upper and lower parts of the lens. As shown in FIG. 8 , FIG. 9 and FIG. 10 , they are three-dimensional side view schematic diagrams, bottom view schematic diagrams and rear view schematic diagrams of the dipped beam lens, respectively.
以上对本发明所提供的LED摩托车近光灯的自由曲面光学透镜进行了详细介绍，使用该透镜时应将LED安装于透镜内侧的圆柱状空腔内，该位置安装方便且利于散热。根据照明需要，透镜可以以LED为轴心微向下倾斜。本发明中应用了各种整体和分离的模型图对具体实施方式进行了阐述，以上所述仅为本发明较佳可行的实施例子而已。对于本领域的技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改善之处。综上所述，本说明书内容不应理解为对本发明的限制。The free-form surface optical lens of the LED motorcycle low beam light provided by the present invention has been introduced in detail above. When using the lens, the LED should be installed in the cylindrical cavity inside the lens. This position is convenient for installation and good for heat dissipation. According to lighting needs, the lens can be slightly tilted downward with the LED as the axis. Various overall and separate model diagrams are used in the present invention to describe the specific implementation manners, and the above descriptions are only preferred and feasible implementation examples of the present invention. For those skilled in the art, according to the idea of the present invention, there will be improvements in the specific implementation and application range. In summary, the contents of this specification should not be construed as limiting the present invention.
Claims (8)
1. The free-form surface optical lens for the LED motorcycle dipped headlight is characterized in that the inner side of the lens is provided with a cavity, the top of the cavity is opposite to an open end, and an LED enters from the open end and is arranged in the cavity when in use; the lens comprises an incident surface and an emergent surface, the incident surface is arranged on the inner side of the lens and consists of a free curved surface at the top of the cavity and a cylindrical surface of the cavity wall; the top plane outside the lens is the emergent surface, and the side surface outside the lens is a peripheral free-form surface; when light at the central part of the LED light source passes through the lens, the light is positioned at the top of the inner side cavity of the lensThe free-form surface and the top plane emergent surface outside the lens are refracted twice and then emergent to the illumination surface; when light at the peripheral part of the LED light source passes through the lens, the light is firstly refracted on a cylindrical surface of the inner side cavity wall of the lens, then is totally reflected on a peripheral free curved surface at the outer side of the lens, then is emitted from a top plane at the outer side of the lens to be refracted, and finally is emitted to an illumination surface; the lens is divided into an upper part and a lower part, wherein the upper part of the lens is mainly used for refracting, reflecting and refracting the light emitted by the LED light source to above the horizontal plane and then irradiating the light to the illumination surface below the horizontal plane; the lower part of the lens is mainly used for refracting, reflecting and refracting the light diffused below the horizontal plane by the LED light source and then converging the light on an illumination surface below the horizontal plane.
2. The free-form optical lens for an LED motorcycle dipped headlight as claimed in claim 1, wherein the shape of the free-form optical lens is determined as follows:
establishing a coordinate system by taking the LED light source as a coordinate origin O, wherein the plane of the bottom surface of the LED is an XOY plane, and an axis which passes through the origin and is vertical to the plane XOY is a Z axis, wherein the plane XOZ is a horizontal plane; the intersection point with the Z axis is o, the plane parallel to the plane XOY is an illumination surface, and the point o is the central point of the illumination surface; firstly, according to the illumination distribution characteristics of motorcycle headlamp low beam lamps on an illumination surface, an illumination area on the illumination surface is set to be a partial circle, namely a sector of 195 degrees, the sector takes a center point of the illumination surface as a circle center, a horizontal line on the left side of the circle center as a left side line and an oblique line which is 15 degrees upward from the right side of the circle center and the horizontal line as a right side line, the partial circle is divided into n equal parts by a girdle band, a light source solid angle is divided into n equal parts, and finally, the free curved surface of the lens is obtained by numerical calculation by applying the law of refraction and reflection.
3. The free-form optical lens for an LED motorcycle passing headlight as claimed in claim 1, wherein the shape of the upper portion of the lens and the lower portion of the lens is determined by:
(1) target illumination area from LED distanceD, total luminous flux of the LED light source is Q, and central light intensity is I0Q/pi; theta in the coordinate system is the included angle between the projection of the emergent ray on the XOY plane and the X axis,
is the included angle between the emergent ray and the positive direction of the Z axis; the radius of the partial circle on the illumination surface is set as r for the upper part of the lens, determined by the plane of YOZup(ii) a Discretizing the coordinates of the illuminated surface by first discretizing the radius r of the circleupIs divided into n portions riRepresents the radius r after the equal divisionupWherein 0 < i < n; then the center point of the illuminating surface is also taken as the center of a circle, and r is respectively taken asiDrawing a circle for the radius, dividing the illumination area into partial circular ring belt areas, wherein on the target illumination area, the energy of each partial circular ring belt area is as follows:
in the formula, Eu·kiRepresenting illumination values, according to the national standard requirements, a constant E being setuFor a predetermined illumination value, a variable k is combinediUsed for controlling the illumination value of a designated area on the illumination surface to form a predetermined illumination distribution, wherein k is more than or equal to 0i≤1，kiThe value of (a) is set according to the illumination requirement on the illumination surface, such as for the brightest region kiFor the edge region k, the value of (A) is in the range of 0.9 to 1iThe value range of (A) is 0-0.1;
similarly, for the lower part of the lens, the radius of the part circle on the illumination surface is rdown(ii) a Discretizing the coordinates of the illuminated surface, i.e. rounding the radius rdownIs divided into m portions rjRepresents the radius r after the equal divisiondownJ is more than 0 and less than or equal to m, and finally, dividing the illumination area into partial circular ring belt areas; the energy of each part of the circular ring belt region on the target illumination region is as follows:
in the formula, constant EdFor a predetermined illumination value, variable kjFor the illumination control parameters, EdAnd kjAnd the values of (A) and (B) are as described above for EuAnd kiThe same process is carried out;
(2) discretizing the solid angle of the central part of the source, i.e. of the lens, for the upper part
The mixture is divided into n parts by weight,to represent
The first part of (a) to (b),
and riOne-to-one correspondence is realized; similarly, the solid angle of the peripheral portion of the light source is discretized, and
the mixture is divided into n parts by weight,to represent
The first part of (a) to (b),
and riOne-to-one correspondence is realized;
for the upper part of the lens, the luminous flux E of the light source is within each angle of the central part of the light source before the light rays enter the lensucAnd a light source peripheral partLuminous flux E of light source in each divided angleulThe total luminous flux of (a) is:
according to the conservation of energy:
Eup＝Euc+Eul
combining the above formulas to obtain the corresponding
And
；
similarly, for the lower part of the lens, the solid angle of the central part of the light source is discretized, i.e.
The mixture is divided into m parts,to represent
The (f) th part(s) of (c),
and rjOne-to-one correspondence is realized; also, the solid angle of the peripheral part of the light source
Discretizing, and separating
The mixture is divided into m parts,
to represent
The first part of (a) to (b),and rjOne-to-one correspondence is realized; the luminous flux E of the light source within each angle of the central part of the light source before the light rays enter the lensdcAnd luminous flux E of the light source within each angle of the peripheral portion of the light sourcedlThe total luminous flux of (a) is:
wherein the value range of theta is 202-356 degrees; according to the conservation of energy:
Edown＝Edc+Edl
combining the above formulas to obtain the corresponding
And
；
(3) and obtaining a normal vector of a point on the curved surface according to the catadioptric law, obtaining a tangent line by using the normal vector, obtaining coordinates of the point on the curved surface through an intersection point of the tangent line and incident light, wherein the vector form of the catadioptric law can be expressed as follows:
wherein,is incident onThe unit vector of the light ray,
is a unit vector of the outgoing light,
is a unit normal vector, and n is the refractive index of the lens;
for the upper part of the lens, a calculation initial point of the lens is determined, and the initial point is determined as follows: at an initial pointThe value is 0 DEG, the height of the free curved surface at the top of the cavity at the inner side of the lens is selected, the height determines the size of the whole lens, then the proper lens thickness is selected according to the height of the free curved surface, a first free curve and a first straight line are obtained by calculation according to the two initial values, the two line segments are on a YOZ plane, the first free curve represents the curve of the free curved surface at the top of the cavity at the inner side of the upper part of the lens on the YOZ plane, the first straight line represents the straight line of the plane at the top of the outer side of the upper part of the lens on the YOZ plane, and the last point of the first free curve and the first straight line corresponds to
The values are all 60 °;
determining the peripheral part of the lens, and drawing a second straight line perpendicular to the Y axis at the last point of the first free curve on the YOZ plane, wherein the size of the intersection point value of the second straight line and the Y axis is the aperture size of the inner cavity of the lens, and the point corresponds to the aperture sizeThe value is 90 °, the second line representing a line on the YOZ plane of the cylindrical surface of the wall of the inner side of the upper part of the lens; of the initial point of the free-form surface of the peripheral part of the lens
The value is set to 90 DEG, and a second free curve on the YOZ plane is obtained by calculation, and the second free curve represents the curve of the free curved surface of the outer periphery of the upper part of the lens on the YOZ plane;
for the lower part of the lens, calculating a third free curve and a third straight line of the central part of the lens according to the height of the free curved surface at the top of the lens cavity and the lens thickness which are selected above, wherein the third free curve represents a curve on the free curved surface at the top of the cavity at the inner side of the lower part of the lens, and the third straight line represents a straight line on a plane at the top of the outer side of the lower part of the lens; a fourth straight line and a fourth curve are also obtained at the peripheral part of the lens, the fourth straight line represents a straight line on the cylindrical surface of the cavity wall at the inner side of the lower part of the lens, and the fourth curve represents a curve on a free curved surface at the outer periphery of the lower part of the lens;
(4) respectively importing the obtained discrete point coordinates of the upper part and the lower part of the lens into mechanical modeling software, and fitting the discrete point coordinates into eight line segments positioned on a YOZ plane, wherein the four line segments are straight lines and the four free curves; combining four line segments of the upper part of the lens into a continuous segmented curve, then rotating the curve 94 degrees around the positive direction of the Z axis, and then rotating 112 degrees around the negative direction of the Z axis, thus obtaining the shape of the upper part of the lens; combining four line segments of the lower part of the lens into a continuous segmented curve, rotating the curve around the positive direction of the Z axis by 68 degrees, and then rotating the curve around the negative direction of the Z axis by 86 degrees, thus obtaining the shape of the lower part of the lens; the free-form surface optical lens shape of the LED motorcycle dipped headlight is finally obtained by processing and fitting the upper part and the lower part of the lens.
4. The free-form optical lens for an LED motorcycle passing headlight as claimed in claim 2, wherein the distance between the point O and the point O is 25 m.
5. The free-form optical lens for an LED motorcycle dipped headlight as claimed in claim 2, wherein the value of θ for the free-form surface of the upper part of the lens is in the range of-4 ° -202 °; for the lower portion of the lens, θ ranges from 202 ° to 356 °.
6. The free-form optical lens for an LED motorcycle dipped headlight as claimed in claim 2,
7. the free-form optical lens for an LED motorcycle passing headlight as claimed in claim 2, wherein a radius of an illumination area of an upper portion of the lens is larger than a radius of an illumination area of a lower portion of the lens, and a bore of a cavity of the upper portion of the lens is larger than a bore of a cavity of the lower portion of the lens.
8. The free-form optical lens for an LED motorcycle dipped headlight as claimed in any one of claims 1 to 7, wherein the lens is made of PMMA or PC or optical glass.
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| CN201210237619.5A CN102901043B (en) | 2012-07-10 | 2012-07-10 | Optical lens with free-form surfaces for LED dipped headlight of motorcycle |
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| CN105589991A (en) * | 2015-12-05 | 2016-05-18 | 中山市华南理工大学现代产业技术研究院 | Design method of free-form surface integrated optical lens for LED motorcycle headlight |
| TWI621803B (en) * | 2017-03-06 | 2018-04-21 | T Y C Brother Industrial Co Ltd | Lamp lens |
| CN108916805A (en) * | 2017-03-22 | 2018-11-30 | 堤维西交通工业股份有限公司 | Lamp lens |
| CN108906542A (en) * | 2018-07-18 | 2018-11-30 | 深圳市华星光电技术有限公司 | Light source curing units and light source curing system |
| CN112393136A (en) * | 2020-11-30 | 2021-02-23 | 浙江光锥科技有限公司 | Method for generating 60-degree beam angle lens structure |
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| CN105972538B (en) * | 2016-06-30 | 2018-10-23 | 中山市华南理工大学现代产业技术研究院 | Combined lens of L ED motorcycle headlamp |
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| CN105589991B (en) * | 2015-12-05 | 2019-06-14 | 中山市华南理工大学现代产业技术研究院 | Design method of free-form surface integrated optical lens for LED motorcycle headlamp |
| TWI621803B (en) * | 2017-03-06 | 2018-04-21 | T Y C Brother Industrial Co Ltd | Lamp lens |
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| CN112393136A (en) * | 2020-11-30 | 2021-02-23 | 浙江光锥科技有限公司 | Method for generating 60-degree beam angle lens structure |
| CN112503434A (en) * | 2020-12-01 | 2021-03-16 | 浙江光锥科技有限公司 | Method for generating lens structure capable of freely distributing light within 48 degrees and lens structure |
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