CN207034990U - A kind of double optical lens with free curved surface of LED automobile dipped headlight - Google Patents

本实用新型公开一种LED汽车近光灯的双自由曲面光学透镜。双自由曲面透镜由两个自由曲面组合而成，第一个自由曲面为入射面,第二个自由曲面为出射面，芯片放置于椭球反射杯的一个焦点处，挡板放在另一个焦点处，透镜放置于挡板之前，芯片发出的光经反射杯的聚光作用后，从另一个焦点射出，由于挡板的作用，杂散光被遮挡住，聚合的光经过透镜的矫正打在照明面上，形成所需要的照明光斑。本实用新型通过两个自由曲面来控制光线的走向及分配，使其照明区域符合国家标准对汽车近光灯的光分布与照度要求。本实用新型解决了现有汽车透镜照明技术中存在的色散严重、色温偏高及光效利用率低等缺陷；其照明区域符合国家标准对汽车近光灯的光分布与照度要求。

The utility model discloses a double free-form surface optical lens of an LED automobile low beam lamp. The double free-form surface lens is composed of two free-form surfaces. The first free-form surface is the incident surface, and the second free-form surface is the exit surface. The chip is placed at one focus of the ellipsoid reflector cup, and the baffle is placed at the other focus. The lens is placed in front of the baffle, and the light emitted by the chip is emitted from another focal point after being concentrated by the reflective cup. Due to the effect of the baffle, the stray light is blocked, and the aggregated light is corrected by the lens and hits the illumination On the surface, the required illumination spot is formed. The utility model controls the direction and distribution of light through two free curved surfaces, so that the lighting area of the utility model meets the requirements of the national standard on light distribution and illuminance of low-beam lamps of automobiles. The utility model solves the defects of severe dispersion, high color temperature and low light efficiency utilization rate existing in the existing automobile lens lighting technology; its lighting area meets the requirements of the national standard for light distribution and illuminance of the low beam lamp of the car.

一种LED汽车近光灯的双自由曲面光学透镜Double free-form surface optical lens for LED automobile low beam

技术领域technical field

本实用新型属于LED照明技术领域，具体涉及一种LED汽车近光灯的双自由曲面光学透镜。The utility model belongs to the technical field of LED lighting, and in particular relates to a double free-form optical lens of an LED automobile low beam lamp.

背景技术Background technique

LED光源具有寿命长、体积小、节能环保、响应时间短、设计自由度大等传统光源无法比拟的优点，因此成为汽车前照灯的第四代光源。LED light source has the incomparable advantages of traditional light sources such as long life, small size, energy saving and environmental protection, short response time, and large design freedom, so it has become the fourth-generation light source of automobile headlights.

在汽车前照灯的设计上，国家标准GB25991-2010对汽车前照灯的配光图形做了规定，目的是防止汽车前照灯干扰对面驶来车辆而造成交通事故。对近光灯来说，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。近光照明面可分为四个区域：ZONEⅠ(Ⅰ区)为具有较大扩散、均匀度良好的基底配光，满足整个路面范围内的最低照明需求；ZONEⅡ、Ⅲ、Ⅳ为具有光能量较为集中、射程较远的中心配光，满足本车道和右边路面(以车辆右行标准为例)较远处的照明需求。在Ⅰ，Ⅱ，Ⅲ和Ⅳ区内，应无影响良好可见度的横向照度变化。而现有的汽车远光灯透镜存在色温偏高和光学效率不高的问题，导致截止线不清晰，截止线附近色散严重，给行车途中的舒适性和安全性带来很大困扰，为了使LED更好地应用于汽车照明领域，这一问题亟需解决。In the design of automobile headlights, the national standard GB25991-2010 stipulates the light distribution pattern of automobile headlights, the purpose is to prevent automobile headlights from interfering with oncoming vehicles and causing traffic accidents. For the dipped beam, it is required to produce a horizontal line and a cut-off line 15° upward on the right side of the horizontal line on the lighting surface 25m away from the headlight. The low-beam lighting surface can be divided into four areas: ZONE Ⅰ (Zone Ⅰ) is a base light distribution with large diffusion and good uniformity, which meets the minimum lighting requirements in the entire road surface; ZONE Ⅱ, Ⅲ, and Ⅳ have light energy relatively Concentrated, long-range central light distribution meets the lighting needs of the lane and the road on the right (take the right-hand traffic standard as an example) farther away. In Zones I, II, III and IV, there shall be no lateral illuminance changes affecting good visibility. However, the existing automotive high beam lens has the problems of high color temperature and low optical efficiency, resulting in unclear cut-off line and serious dispersion near the cut-off line, which brings great troubles to the comfort and safety of driving. LED is better used in the field of automotive lighting, this problem needs to be solved urgently.

实用新型内容Utility model content

本实用新型针对上述存在的问题，提供了一种LED汽车近光灯的双自由曲面光学透镜。Aiming at the above-mentioned problems, the utility model provides an optical lens with double free-form surfaces for an LED automobile low beam lamp.

本实用新型的目的至少通过如下技术方案之一实现。The purpose of the utility model is at least achieved by one of the following technical solutions.

一种LED汽车近光灯的双自由曲面光学透镜，近光灯透镜上下两个面都是自由曲面，第一个自由曲面为入射面，替换单自由曲面中的入射平面，第二个自由曲面为出射面，芯片放置于椭球反射杯的一个焦点处，挡板放在另一个焦点处，透镜放置于挡板之前，芯片发出的光经反射杯的聚光作用后，从另一个焦点射出，由于挡板的作用，杂散光被遮挡住，聚合的光经过透镜的矫正打在照明面上，每个自由曲面都可以灵活的对光线进行矫正，使照明光斑更加均匀，且曲面的外观更加圆滑；根据国家标准中对汽车灯近光灯照度值的分布要求，设定利用多大角度的芯片出光角，在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，在截止线下方产生一个近似半椭圆的照明区，将照明区域进行环形划分，即将椭圆区域划分成3份同心椭圆环，设定椭圆环区域内的照度值，计算出光线经反射杯反射后的的出光角度和目标照明面的映射关系，由映射关系即可得出光线的矫正角度，预先设定第一个自由曲面和第二个自由曲面的角度矫正比，根据角度矫正比，可确定第一自由曲面和第二自由曲面各自的矫正角度，即可确定两个自由曲面的出射光线，利用迭代计算公式计算出第一个自由曲面上的点，用第一个自由曲面上的点作为入射光线的起始点，再用迭代公式计算出第二个自由曲面上的点，将两个曲面上的点导入到三维软件中，即可得到透镜实体。An optical lens with double free-form surfaces for low-beam lights of LED cars. The upper and lower surfaces of the low-beam lens are free-form surfaces. The first free-form surface is the incident surface, which replaces the incident plane in the single free-form surface. As the exit surface, the chip is placed at one focal point of the ellipsoid reflective cup, the baffle is placed at the other focal point, and the lens is placed in front of the baffle, and the light emitted by the chip is emitted from the other focal point after being concentrated by the reflective cup , due to the function of the baffle, the stray light is blocked, and the aggregated light is corrected by the lens and hits the lighting surface. Each free-form surface can flexibly correct the light, so that the lighting spot is more uniform, and the appearance of the curved surface is better. Smooth; according to the distribution requirements of the illuminance value of the low-beam light of the car lamp in the national standard, set the chip light-emitting angle of what angle to use, and generate a horizontal line and a cut-off line of 15° upward on the right side of the horizontal line on the lighting surface. An approximately semi-elliptical lighting area is generated below, and the lighting area is divided into rings, that is, the elliptical area is divided into three concentric elliptical rings, the illuminance value in the elliptical ring area is set, and the light output angle after the light is reflected by the reflective cup is calculated. The mapping relationship with the target lighting surface, the correction angle of the light can be obtained from the mapping relationship, the angle correction ratio of the first free-form surface and the second free-form surface is preset, and the first free-form surface can be determined according to the angle correction ratio and the respective correction angles of the second free-form surface, the outgoing rays of the two free-form surfaces can be determined, and the point on the first free-form surface is calculated by using the iterative calculation formula, and the point on the first free-form surface is used as the starting point of the incident ray Then use the iterative formula to calculate the point on the second free surface, and import the points on the two surfaces into the 3D software to obtain the lens entity.

双自由曲面透镜能使透过的光线色温稳定，光斑均匀，截止线清晰，且无色散现象。透镜的外形结构为凹凸形，第一个自由曲面向透镜内部凹，第二个自由曲面向外凸，整个透镜可认为是由球面透镜中的正负透镜组合而成的胶合透镜，胶合透镜可以很好的矫正色差，所以在光线通过双自由曲面时，能很好的稳定光斑的色温，光斑不会出现明显的偏蓝或偏黄现象，由于挡板的作用，光斑会形成一水平线和水平线右侧向上15°的明暗截止线，且两个自由曲面都参与光线矫正，可以做到从焦点发出的光线的出光角度和目标平面的映射关系更加准确，无杂散光，截止线更加清晰且无色散现象。The double free-form surface lens can make the color temperature of the transmitted light stable, the light spot is uniform, the cut-off line is clear, and there is no dispersion phenomenon. The shape of the lens is concave-convex. The first free curved surface is concave inside the lens, and the second free curved surface is convex outward. The whole lens can be considered as a cemented lens composed of positive and negative lenses in the spherical lens. The cemented lens can be Very good correction of chromatic aberration, so when the light passes through the double free-form surface, the color temperature of the light spot can be well stabilized, the light spot will not appear obvious bluish or yellowish phenomenon, due to the effect of the baffle, the light spot will form a horizontal line and a horizontal line The light and dark cut-off line is 15° upward on the right side, and both free-form surfaces participate in light correction, so that the mapping relationship between the light angle of the light emitted from the focal point and the target plane is more accurate, there is no stray light, and the cut-off line is clearer and without dispersion phenomenon.

双自由曲面透镜由透明材料制成，透明材料为PMMA或PC，透镜的上下两个面为自由曲面，两者间的过渡面为圆柱面，圆柱面可以方便的与支架相连，方便透镜的定位，且不会影响光学效果。The double free-form surface lens is made of transparent material, the transparent material is PMMA or PC, the upper and lower surfaces of the lens are free-form surfaces, the transition surface between them is a cylindrical surface, and the cylindrical surface can be easily connected with the bracket to facilitate the positioning of the lens , and will not affect the optical effect.

双自由曲面透镜的入射面为自由曲面，其曲面的形状确定如下；以投射式LED汽车近光灯的椭球反射器的第二焦点为坐标原点建立直角坐标系，以过原点并平行于自由曲面透镜入射面的平面为XOY平面，垂直于芯片发光面的方向为Y轴，以所述自由曲面透镜厚度方向所在直线为Z轴；目标照明面在坐标原点前方25m处，照明面所在平面为xoy平面，照明面的中心为o点；目标照明面根据汽车用LED前照灯的国家标准(GB25991-2010)分为Ⅰ区、Ⅱ区、Ⅲ区和Ⅳ区，每个区域都有对应的照度要求值，设定其目标照明区域是半椭圆形，椭圆长半轴为a，短半轴为b；对照明面的坐标进行环形划分，首先把椭圆长半轴a和短半轴b分别等分成3份，a_i和b_i分别表示等分后长半轴a的第i份和短半轴b的第i份，其中0＜i≤3；然后以照明面中心点为中心，分别以a_i为长半轴、b_i为短半轴画椭圆，则将照明区域划分成3份椭圆形环带区域；按芯片的总光通量和芯片的光强分布，设定芯片的光能利用角，设出射光线的中心光强为I₀，其中θ为出射光线与Z轴正方向的夹角，为出射光线在XOY平面上的投影与X轴的夹角，接着再将角度划分，即把角分成n份，表示的第i份(即将截止线下的195°分成195份)，不同的对应不同的照明半径R，R的计算表达式为：The incident surface of the double free-form surface lens is a free-form surface, and the shape of the surface is determined as follows; the second focal point of the ellipsoidal reflector of the projection-type LED automobile low-beam light is used as the coordinate origin to establish a rectangular coordinate system, passing through the origin and parallel to the free-form surface The plane of the incident surface of the curved surface lens is the XOY plane, the direction perpendicular to the light-emitting surface of the chip is the Y axis, and the straight line where the thickness direction of the free-form surface lens is located is the Z axis; the target lighting surface is 25m in front of the coordinate origin, and the plane where the lighting surface is located is The xoy plane, the center of the lighting surface is point o; the target lighting surface is divided into zone Ⅰ, zone Ⅱ, zone Ⅲ and zone Ⅳ according to the national standard of LED headlights for automobiles (GB25991-2010), and each zone has a corresponding Illumination requirement value, set the target lighting area to be a semi-ellipse, the semi-major axis of the ellipse is a, and the semi-short axis is b; the coordinates of the lighting surface are divided into rings, firstly, the semi-major axis a and the semi-short axis b of the ellipse are respectively Divide into 3 equal parts, a _i and b _i respectively represent the i-th part of the major semi-axis a and the i-th part of the minor semi-axis b after equal division, where 0<i≤3; then take the center point of the lighting surface as the center, respectively Draw an ellipse with a _i as the long semi-axis and b _i as the short semi-axis, then divide the lighting area into three elliptical ring areas; set the light energy utilization of the chip according to the total luminous flux of the chip and the light intensity distribution of the chip angle, set the central light intensity of the outgoing ray as I ₀ , where θ is the angle between the outgoing ray and the positive direction of the Z axis, is the angle between the projection of the outgoing light on the XOY plane and the X axis, and then divide the angle, that is, the angle divided into n parts, express The i-th part of (that is, the 195° under the cut-off line is divided into 195 parts), the different Corresponding to different lighting radii R, the calculation expression of R is:

将椭球反射器的第二焦点发出的光线按照角度θ₁、θ₂、θ₃分为3个部分分别投射到照明面上对应的三个环带区域；在固定时，即R_i＝r，椭球反射器第二焦点发出的光与Z轴方向夹角为θ₁的那部分光线入射到透镜后照射在离照明面中心距离为r₁的位置，与Z轴线夹角小于θ₁的那部分光线经透镜后照射在照明面的位置与照明面中心距离小于r₁，将第一部分光线对应的角度θ₁等分成i份，每一个θ₁在半径r₁上也相应的分成i份,这样相应的得到了数组θ₁(i)和数组r₁(i)，那么第一区域出射光和照明面上的照度的能量守恒表达式为：Divide the light emitted by the second focal point of the ellipsoidal reflector into three parts according to the angles θ ₁ , θ ₂ , and θ ₃ and project them onto the corresponding three annular zones on the lighting surface; When it is fixed, that is, R _i = r, the part of the light emitted by the second focal point of the ellipsoidal reflector and the Z-axis direction with an angle of θ ₁ is incident on the lens and irradiated at a position at a distance of r ₁ from the center of the illuminating surface, and The part of the light with an included angle of Z axis smaller _than θ ₁ passes through the lens and irradiates the position _of the lighting surface and the distance from the center of the lighting surface is less than r ₁ . ₁ is also correspondingly divided into i parts, so that the array θ ₁ (i) and the array r ₁ (i) are correspondingly obtained, then the energy conservation expression of the outgoing light in the first area and the illuminance on the illuminated surface is:

同理，从椭球反射器第二焦点发出的光与Z轴方向夹角为θ₁～θ₂之间的那部分光线入射到透镜后照射在离照明面中心距离为r₁～r₂的位置，将这部分光线等分成j份，对应每一个角度在半径上也分成j份，这样相应的得到了数组θ₂(j)和数组r₂(j)，则该区域出射光和照明面上的照度的能量守恒表达式为：Similarly, the part of the light emitted from the second focal point of the ellipsoidal reflector and the Z-axis direction at an angle between θ ₁ ~ θ ₂ is incident on the lens and irradiated on the center of the illuminating surface at a distance of r ₁ ~ r ₂ Divide this part of the light into j parts, corresponding to each angle in the radius also divided into j parts, so that the array θ ₂ (j) and the array r ₂ (j) are correspondingly obtained, then the outgoing light and the illuminated surface of this area The energy conservation expression of the illuminance on is:

同理，从椭球反射器第二焦点发出的光与Z轴方向夹角为θ₂～θ₃之间的那部分光线入射到透镜后照射在离照明面中心距离为r₂～r₃的位置，将这部分光线等分成k份，对应每一个角度在半径上也分成k份，这样就得到了数组θ₃(k)和数组r₃(k)，可得该区域出射光和照明面上的照度的能量守恒表达式为Similarly, the part of the light emitted from the second focal point of the ellipsoidal reflector and the Z-axis direction at an angle between θ ₂ ~ θ ₃ is incident on the lens and irradiated on the center of the illuminating surface at a distance of r ₂ ~ r ₃ Divide this part of the light into k parts, corresponding to each angle in the radius also divided into k parts, so that the array θ ₃ (k) and the array r ₃ (k) are obtained, and the outgoing light and the illumination surface of the area can be obtained The energy conservation expression of the illuminance above is

计算上面三个表达式，分别得到各区域半径与出射光角度的关系；改变不同的值，得到不同的照明半径，依照上面的计算方法，即可得到从焦点出射的光线的出光角度与照明面的对应关系。设定第一个自由曲面和第二个自由曲面的角度矫正比为M：N，即设定两个自由曲面各自的矫正角度,可得出经过第一个自由曲面后的出射光线的角度，如已知入射光线的角度为θ_i，则出射光线的角度为Cθ_i，系数C的计算公式为Calculate the above three expressions to obtain the relationship between the radius of each area and the angle of the outgoing light; change the different Value, to get different lighting radii, according to the above calculation method, you can get the corresponding relationship between the light angle of the light emitted from the focus and the lighting surface. Set the angle correction ratio of the first free-form surface and the second free-form surface to M:N, that is, set the respective correction angles of the two free-form surfaces, and the angle of the outgoing light after passing through the first free-form surface can be obtained. If it is known that the angle of the incident ray is θ _i , then the angle of the outgoing ray is Cθ _i , and the formula for calculating the coefficient C is

C＝N/(M+N)C=N/(M+N)

这样我们就可计算出第一个自由曲面的入射光线和出射光线的对应关系。为了计算出自由曲面上所有点的坐标，先设定一个起始点和固定角的值，即确定第二焦点与透镜底面中心点的距离，初始点确定后，由折射定律求出初始点的法向量，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第二个点的坐标，折射定律的矢量形式可表示为：In this way, we can calculate the corresponding relationship between the incident ray and the outgoing ray of the first free-form surface. In order to calculate the coordinates of all points on the free surface, first set a starting point and a fixed angle The value of is to determine the distance between the second focal point and the center point of the lens bottom surface. After the initial point is determined, the normal vector of the initial point is obtained by the law of refraction, and the tangent is obtained by using this normal vector. The curve is obtained by obtaining the intersection point of the tangent line and the incident ray The coordinates of the second point on , the vector form of the law of refraction can be expressed as:

其中，为入射光线单位向量，为出射光线单位向量，为单位法向量，n为透镜折射率；通过此迭代计算公式，可依次计算出曲线上其他的点，由此可得到一条完整的自由曲线；通过分别固定不同的角的值，便得到自由曲面出射面上的一系列自由曲线，最后由这些自由曲线组成透镜的第一个自由曲面。in, is the unit vector of the incident ray, is the unit vector of the outgoing ray, is the unit normal vector, n is the refractive index of the lens; through this iterative calculation formula, other points on the curve can be calculated in turn, and a complete free curve can be obtained; by fixing different angles value, a series of free curves on the exit surface of the free-form surface are obtained, and finally the first free-form surface of the lens is composed of these free curves.

双自由曲面透镜的出射面也为自由曲面，第二个自由曲面的形状确定如下；由第一自由曲面确定过程可得从焦点出射的光线的出光角度和照明面各区域的对应关系，以及第一个自由曲面上离散点的坐标，我们将第一个自由曲面上的离散点作为光线的出射点，第一个自由曲面上离散点的出射光线即为第二个自由曲面上点的入射光线，第二个自由曲面上离散点与目标平面上对应点的连线即为出射光线，如此我们可以得到第二个自由曲面的入射光线和出射光线的对应关系。为了计算出自由曲面上所有点的坐标，先设定一个起始点和固定角的值，即确定透镜中心的厚度，初始点确定后，由折射定律求出初始点的法向量，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第二个点的坐标，通过此迭代计算公式，可依次计算出曲线上其他的点，由此可得到一条完整的自由曲线；通过分别固定不同的角的值，便得到自由曲面出射面上的一系列自由曲线，最后由这些自由曲线组成透镜的第二个自由曲面。The exit surface of the double free-form surface lens is also a free-form surface, and the shape of the second free-form surface is determined as follows; through the determination process of the first free-form surface, the corresponding relationship between the exit angle of the light emitted from the focal point and each area of the illumination surface can be obtained, and the second The coordinates of a discrete point on a free surface, we take the discrete point on the first free surface as the exit point of the light, and the outgoing light of the discrete point on the first free surface is the incident light of the point on the second free surface , the line connecting the discrete point on the second free-form surface and the corresponding point on the target plane is the outgoing ray, so we can get the corresponding relationship between the incident ray and the outgoing ray on the second free-form surface. In order to calculate the coordinates of all points on the free surface, first set a starting point and a fixed angle The value of is to determine the thickness of the center of the lens. After the initial point is determined, the normal vector of the initial point is obtained by the law of refraction, and the tangent is obtained by using this normal vector. The second point on the curve is obtained by obtaining the intersection point of the tangent line and the incident ray. Coordinates, through this iterative calculation formula, other points on the curve can be calculated in turn, so that a complete free curve can be obtained; by fixing different angles respectively value, a series of free curves on the exit surface of the free-form surface are obtained, and finally the second free-form surface of the lens is composed of these free curves.

与现有技术相比，本实用新型具有如下优点和技术效果：Compared with the prior art, the utility model has the following advantages and technical effects:

该透镜入射面和出射面皆为自由曲面，两个自由曲面皆能灵活的对光线进行矫正，且光效利用率更高，无明显的色散现象，能很好的稳定光斑的色温，光斑不会出现明显的偏蓝或偏黄现象，由于挡板的作用，光斑会形成一水平线和水平线右侧向上15°的明暗截止线，且两个自由曲面都参与光线矫正，可以做到从焦点发出的光线的出光角度和目标平面的映射关系更加准确，无杂散光，截止线更加清晰。本实用新型解决了现有汽车透镜照明技术中存在的色散严重、色温偏高及光效利用率低等缺陷；通过透镜的两个自由曲面来控制光线的走向及分配，使其照明区域符合国家标准对汽车近光灯的光分布与照度要求。Both the incident surface and the outgoing surface of the lens are free-form surfaces, both free-form surfaces can flexibly correct the light, and the light efficiency utilization rate is higher, there is no obvious dispersion phenomenon, and the color temperature of the light spot can be well stabilized, and the light spot is not There will be obvious bluish or yellowish phenomenon. Due to the effect of the baffle, the light spot will form a horizontal line and a 15° upward cut-off line on the right side of the horizontal line, and both free-form surfaces participate in light correction, which can be emitted from the focal point The mapping relationship between the light output angle of the light and the target plane is more accurate, there is no stray light, and the cut-off line is clearer. The utility model solves the defects of severe dispersion, high color temperature and low light efficiency utilization rate in the existing automobile lens lighting technology; the direction and distribution of light are controlled by two free curved surfaces of the lens, so that the lighting area meets the national standard. Light distribution and illuminance requirements of automobile dipped headlights.

附图说明Description of drawings

图1为实施方式中投射式近光灯系统的正视图。Fig. 1 is a front view of a projection low beam system in an embodiment.

图2为实施方式中投射式近光灯系统的侧视图。Fig. 2 is a side view of the projection low beam system in the embodiment.

图3为实施方式中透镜的正视图。Fig. 3 is a front view of the lens in the embodiment.

图4为实施方式中透镜的剖面图。Fig. 4 is a cross-sectional view of a lens in the embodiment.

图5为实施方式中第二焦点出来的光线投射到照明面时的光线划分区域图。Fig. 5 is an area diagram of the division of light when the light from the second focal point is projected onto the lighting surface in the embodiment.

具体实施方式detailed description

以下结合附图和实例对本实用新型的实施作进一步说明，但本实用新型的实施和保护不限于此。The implementation of the utility model will be further described below in conjunction with the accompanying drawings and examples, but the implementation and protection of the utility model are not limited thereto.

一种LED汽车近光灯的双自由曲面光学透镜，透镜上下两个面都是自由曲面，第一个自由曲面为入射面，替换单自由曲面中的入射平面，第二个自由曲面为出射面，芯片放置于椭球反射杯的一个焦点处，挡板放在另一个焦点处，透镜放置于挡板之前，芯片发出的光经反射杯的聚光作用后，从另一个焦点射出，由于挡板的作用，杂散光被遮挡住，聚合的光经过透镜的矫正打在照明面上，每个自由曲面都可以灵活的对光线进行矫正，使照明光斑更加均匀，且曲面外观圆滑；根据国家标准中对汽车灯近光灯照度值的分布要求，设定利用多大角度的芯片出光角，在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，在截止线下方产生一个近似半椭圆的照明区，将照明区域进行环形划分，即将椭圆区域划分成3份同心椭圆环，设定椭圆环区域内的照度值，计算出光线经反射杯反射后的的出光角度和目标照明面的映射关系，由映射关系即可得出光线的矫正角度，预先设定第一个自由曲面和第二个自由曲面的角度矫正比，根据角度矫正比，可确定第一自由曲面和第二自由曲面各自的矫正角度，即可确定两个自由曲面的出射光线，利用迭代计算公式计算出第一个自由曲面上的点，用第一个自由曲面上的点作为入射光线的起始点，再用迭代公式计算出第二个自由曲面上的点，将两个曲面上的点导入到三维软件中，即可得到透镜实体。An optical lens with double free-form surfaces for LED automobile low-beam lights. The upper and lower surfaces of the lens are free-form surfaces. The first free-form surface is the incident surface, which replaces the incident plane in the single free-form surface, and the second free-form surface is the exit surface. The chip is placed at one focal point of the ellipsoidal reflector cup, the baffle is placed at the other focal point, and the lens is placed in front of the baffle. The role of the board, the stray light is blocked, the aggregated light is corrected by the lens and hits the lighting surface, and each free-form surface can flexibly correct the light, so that the lighting spot is more uniform, and the appearance of the curved surface is smooth; according to the national standard For the distribution requirements of the illuminance value of the low-beam headlights of automobile lamps, set the chip light angle of what angle to use, generate a horizontal line on the lighting surface and a light-dark cut-off line 15° upward on the right side of the horizontal line, and generate an approximate half-light cut-off line below the cut-off line. For the elliptical lighting area, the lighting area is divided into rings, that is, the elliptical area is divided into three concentric elliptical rings, the illuminance value in the elliptical ring area is set, and the light output angle after the light is reflected by the reflective cup and the target lighting surface are calculated. Mapping relationship, the correction angle of light can be obtained from the mapping relationship, the angle correction ratio of the first free-form surface and the second free-form surface is preset, and the first free-form surface and the second free-form surface can be determined according to the angle correction ratio The respective correction angles can determine the outgoing rays of the two free-form surfaces, use the iterative calculation formula to calculate the point on the first free-form surface, use the point on the first free-form surface as the starting point of the incident light, and then use the iterative calculation formula The formula calculates the points on the second free surface, and the points on the two surfaces are imported into the 3D software to obtain the lens entity.

本实例的透镜的上下两个面为自由曲面，两者间的过渡面为圆柱面，圆柱面能与支架相连，方便透镜的定位，且不会影响光学效果。双自由曲面透镜能使透过的光线色温稳定，光斑均匀，截止线清晰，且无色散现象。透镜的外形结构为凹凸形，第一个自由曲面向透镜内部凹，第二个自由曲面向外凸，整个透镜是由球面透镜中的正负透镜组合而成的胶合透镜，胶合透镜可以很好的矫正色差，所以在光线通过双自由曲面时，能很好的稳定光斑的色温，光斑不会出现明显的偏蓝或偏黄现象，由于挡板的作用，光斑会形成一水平线和水平线右侧向上15°的明暗截止线，且两个自由曲面都参与光线矫正，可以做到从焦点发出的光线的出光角度和目标平面的映射关系更加准确，无杂散光，截止线更加清晰且无色散现象。The upper and lower surfaces of the lens in this example are free-form surfaces, and the transition surface between them is a cylindrical surface. The cylindrical surface can be connected with the bracket to facilitate the positioning of the lens without affecting the optical effect. The double free-form surface lens can make the color temperature of the transmitted light stable, the light spot is uniform, the cut-off line is clear, and there is no dispersion phenomenon. The shape of the lens is concave-convex. The first free curved surface is concave inside the lens, and the second free curved surface is convex outward. The whole lens is a cemented lens composed of positive and negative lenses in the spherical lens. The cemented lens can be very good Correcting chromatic aberration, so when the light passes through the double free-form surface, the color temperature of the light spot can be well stabilized, and the light spot will not appear obvious bluish or yellowish phenomenon. Due to the effect of the baffle, the light spot will form a horizontal line and the right side of the horizontal line The light and dark cut-off line is 15° upward, and both free-form surfaces participate in light correction, so that the mapping relationship between the light output angle of the light emitted from the focal point and the target plane is more accurate, there is no stray light, the cut-off line is clearer, and there is no dispersion phenomenon .

入射面为自由曲面，其曲面的形状确定如下；The incident surface is a free-form surface, and the shape of the surface is determined as follows;

以投射式LED汽车近光灯的椭球反射器的第二焦点为坐标原点建立直角坐标系，以过原点并平行于自由曲面透镜入射面的平面为XOY平面，垂直于芯片发光面的方向为Y轴，以所述自由曲面透镜厚度方向所在直线为Z轴；目标照明面在坐标原点前方25m处，照明面所在平面为xoy平面，照明面的中心为o点；目标照明面根据汽车用LED前照灯的国家标准(GB25991-2010)分为Ⅰ区、Ⅱ区、Ⅲ区和Ⅳ区，每个区域都有对应的照度要求值，设定其目标照明区域是半椭圆形，椭圆长半轴为a，短半轴为b；对照明面的坐标进行环形划分，首先把椭圆长半轴a和短半轴b分别等分成3份，a_i和b_i分别表示等分后长半轴a的第i份和短半轴b的第i份，其中0＜i≤3；然后以照明面中心点为中心，分别以a_i为长半轴、b_i为短半轴画椭圆，则将照明区域划分成3份椭圆形环带区域；按芯片的总光通量和芯片的光强分布，设定芯片的光能利用角，设出射光线的中心光强为I₀，其中θ为出射光线与Z轴正方向的夹角，为出射光线在XOY平面上的投影与X轴的夹角，接着再将角度划分，即把角分成n份，表示的第i份，即将截止线下的195°分成195份，不同的对应不同的照明半径R，R的计算表达式为：The Cartesian coordinate system is established with the second focal point of the ellipsoidal reflector of the projection-type LED car low beam as the coordinate origin, the plane passing through the origin and parallel to the incident surface of the free-form surface lens is the XOY plane, and the direction perpendicular to the light-emitting surface of the chip is Y-axis, the straight line where the thickness direction of the free-form surface lens is located is the Z-axis; the target lighting surface is 25m ahead of the coordinate origin, the plane where the lighting surface is located is the xoy plane, and the center of the lighting surface is o point; the target lighting surface is based on the automotive LED The national standard for headlights (GB25991-2010) is divided into Zone I, Zone II, Zone III and Zone IV. Each zone has a corresponding illuminance requirement value. The target lighting zone is set to be a semi-ellipse, and the length of the ellipse is half The axis is a, and the semi-minor axis is b; the coordinates of the lighting surface are circularly divided. Firstly, the semi-major axis a and the semi-minor axis b of the ellipse are divided into three parts, and a _i and b _i respectively represent the semi-major axis after equal division. The i-th part of a and the i-th part of the semi-minor axis b, where 0<i≤3; then take the center point of the illuminated surface as the center, and draw an ellipse with a _i as the major semi-axis and b _i as the minor semi-axis, then Divide the lighting area into three elliptical ring areas; set the light energy utilization angle of the chip according to the total luminous flux of the chip and the light intensity distribution of the chip, and set the central light intensity of the outgoing light to I ₀ , where θ is the outgoing light The angle with the positive direction of the Z axis, is the angle between the projection of the outgoing light on the XOY plane and the X axis, and then divide the angle, that is, the angle divided into n parts, express The i-th part, that is, the 195° below the cut-off line is divided into 195 parts, different Corresponding to different lighting radii R, the calculation expression of R is:

将椭球反射器的第二焦点发出的光线按照角度θ₁、θ₂、θ₃分为3个部分分别投射到照明面上对应的三个环带区域；在固定时，即R_i＝r，椭球反射器第二焦点发出的光与Z轴方向夹角为θ₁的那部分光线入射到透镜后照射在离照明面中心距离为r₁的位置，与Z轴线夹角小于θ₁的那部分光线经透镜后照射在照明面的位置与照明面中心距离小于r₁，将第一部分光线对应的角度θ₁等分成i份，每一个θ₁在半径r₁上也相应的分成i份,这样相应的得到了数组θ₁(i)和数组r₁(i)，那么第一区域出射光和照明面上的照度的能量守恒表达式为：Divide the light emitted by the second focal point of the ellipsoidal reflector into three parts according to the angles θ ₁ , θ ₂ , and θ ₃ and project them onto the corresponding three annular zones on the lighting surface; When it is fixed, that is, R _i = r, the part of the light emitted by the second focal point of the ellipsoidal reflector and the Z-axis direction with an angle of θ ₁ is incident on the lens and irradiated at a position at a distance of r ₁ from the center of the illuminating surface, and The part of the light with an included angle of Z axis smaller _than θ ₁ passes through the lens and irradiates the position _of the lighting surface and the distance from the center of the lighting surface is less than r ₁ . ₁ is also correspondingly divided into i parts, so that the array θ ₁ (i) and the array r ₁ (i) are correspondingly obtained, then the energy conservation expression of the outgoing light in the first area and the illuminance on the illuminated surface is:

同理，从椭球反射器第二焦点发出的光与Z轴方向夹角为θ₁～θ₂之间的那部分光线入射到透镜后照射在离照明面中心距离为r₁～r₂的位置，将这部分光线等分成j份，对应每一个角度在半径上也分成j份，这样相应的得到了数组θ₂(j)和数组r₂(j)，则该区域出射光和照明面上的照度的能量守恒表达式为：Similarly, the part of the light emitted from the second focal point of the ellipsoidal reflector and the Z-axis direction at an angle between θ ₁ ~ θ ₂ is incident on the lens and irradiated on the center of the illuminating surface at a distance of r ₁ ~ r ₂ Divide this part of the light into j parts, corresponding to each angle in the radius also divided into j parts, so that the array θ ₂ (j) and the array r ₂ (j) are correspondingly obtained, then the outgoing light and the illuminated surface of this area The energy conservation expression of the illuminance on is:

同理，从椭球反射器第二焦点发出的光与Z轴方向夹角为θ₂～θ₃之间的那部分光线入射到透镜后照射在离照明面中心距离为r₂～r₃的位置，将这部分光线等分成k份，对应每一个角度在半径上也分成k份，这样就得到了数组θ₃(k)和数组r₃(k)，可得该区域出射光和照明面上的照度的能量守恒表达式为Similarly, the part of the light emitted from the second focal point of the ellipsoidal reflector and the Z-axis direction at an angle between θ ₂ ~ θ ₃ is incident on the lens and irradiated on the center of the illuminating surface at a distance of r ₂ ~ r ₃ Divide this part of the light into k parts, corresponding to each angle in the radius also divided into k parts, so that the array θ ₃ (k) and the array r ₃ (k) are obtained, and the outgoing light and the illumination surface of the area can be obtained The energy conservation expression of the illuminance above is

计算上面三个表达式，分别得到各区域半径与出射光角度的关系；改变不同的值，得到不同的照明半径，进而可得到从焦点出射的光线的出光角度与照明面的对应关系；设定第一个自由曲面和第二个自由曲面的角度矫正比为M：N，即设定两个自由曲面各自的矫正角度,可得出经过第一个自由曲面后的出射光线的角度，如已知入射光线的角度为θ_i，则出射光线的角度为Cθ_i，系数C的计算公式为Calculate the above three expressions to obtain the relationship between the radius of each area and the angle of the outgoing light; change the different value, to obtain different illumination radii, and then to obtain the corresponding relationship between the light exit angle of the light emitted from the focal point and the illumination surface; set the angle correction ratio of the first free-form surface and the second free-form surface as M:N, that is, set By setting the respective correction angles of the two free-form surfaces, the angle of the outgoing ray after passing through the first free-form surface can be obtained. If the angle of the incident ray is known to be θ _i , then the angle of the outgoing ray is Cθ _i . Calculation of the coefficient C The formula is

C＝N/(M+N)；C=N/(M+N);

进而得出第一个自由曲面的入射光线和出射光线的对应关系；为了计算出自由曲面上所有点的坐标，先设定一个起始点和固定角的值，即确定第二焦点与透镜底面中心点的距离，初始点确定后，由折射定律求出初始点的法向量，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第二个点的坐标，折射定律的矢量形式可表示为：Then get the corresponding relationship between the incident light and the outgoing light of the first free-form surface; in order to calculate the coordinates of all points on the free-form surface, first set a starting point and a fixed angle The value of is to determine the distance between the second focal point and the center point of the lens bottom surface. After the initial point is determined, the normal vector of the initial point is obtained by the law of refraction, and the tangent is obtained by using this normal vector. The curve is obtained by obtaining the intersection point of the tangent line and the incident ray The coordinates of the second point on , the vector form of the law of refraction can be expressed as:

其中，为入射光线单位向量，为出射光线单位向量，为单位法向量，n为透镜折射率；通过此迭代计算公式，可依次计算出曲线上其他的点，由此可得到一条完整的自由曲线；通过分别固定不同的角的值，便得到自由曲面出射面上的一系列自由曲线，最后由这些自由曲线组成透镜的第一个自由曲面。in, is the unit vector of the incident ray, is the unit vector of the outgoing ray, is the unit normal vector, n is the refractive index of the lens; through this iterative calculation formula, other points on the curve can be calculated in turn, and a complete free curve can be obtained; by fixing different angles value, a series of free curves on the exit surface of the free-form surface are obtained, and finally the first free-form surface of the lens is composed of these free curves.

透镜的出射面也为自由曲面，第二个自由曲面的形状确定如下；The exit surface of the lens is also a free-form surface, and the shape of the second free-form surface is determined as follows;

由第一个自由曲面的确定过程可得从焦点出射的光线的出光角度和照明面各区域的对应关系，以及第一个自由曲面上离散点的坐标，将第一个自由曲面上的离散点作为光线的出射点，第一个自由曲面上离散点的出射光线即为第二个自由曲面上点的入射光线，第二个自由曲面上离散点与目标平面上对应点的连线即为出射光线，进而得到第二个自由曲面的入射光线和出射光线的对应关系；为了计算出自由曲面上所有点的坐标，先设定一个起始点和固定角的值，即确定透镜中心的厚度，初始点确定后，由折射定律求出初始点的法向量，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第二个点的坐标，通过此迭代计算公式，可依次计算出曲线上其他的点，由此可得到一条完整的自由曲线；通过分别固定不同的角的值，便得到自由曲面出射面上的一系列自由曲线，最后由这些自由曲线组成透镜的第二个自由曲面。From the determination process of the first free-form surface, the corresponding relationship between the light exit angle of the light emitted from the focal point and each area of the illumination surface, and the coordinates of the discrete points on the first free-form surface can be obtained, and the discrete points on the first free-form surface As the exit point of the ray, the outgoing ray of the discrete point on the first free-form surface is the incident ray of the point on the second free-form surface, and the line connecting the discrete point on the second free-form surface and the corresponding point on the target plane is the outgoing ray Light, and then get the corresponding relationship between the incident light and the outgoing light of the second free-form surface; in order to calculate the coordinates of all points on the free-form surface, first set a starting point and a fixed angle The value of is to determine the thickness of the center of the lens. After the initial point is determined, the normal vector of the initial point is obtained by the law of refraction, and the tangent is obtained by using this normal vector. The second point on the curve is obtained by obtaining the intersection point of the tangent line and the incident ray. Coordinates, through this iterative calculation formula, other points on the curve can be calculated in turn, so that a complete free curve can be obtained; by fixing different angles respectively value, a series of free curves on the exit surface of the free-form surface are obtained, and finally the second free-form surface of the lens is composed of these free curves.

如图1和图2所示，投射式近光灯由四部分组成，包括芯片1，椭球反射杯2，能形成15°截止线的挡板3，双自由曲面透镜4；如图3和图4所示，双自由曲面透镜由第一自由曲面41、第二自由曲面42两个自由曲面和一个圆柱侧面组成，两个自由曲面都参与光线角度的矫正，圆柱侧面便于把透镜固定在支架上。如图5所示，为光线从焦点射出后的配光图，按照国标的配光要求和照度分布，将照明面区域设定为以照明面中心点为中心的半椭圆形区域，然后对照明区域进行划分，接着根据能量守恒，得到各区域半径与出射光角度的关系，设定两个自由曲面的角度矫正比，计算出C值，按C值的大小和从焦点出射光的角度与照明面的对应关系，利用迭代计算公式，计算出第一个自由曲面的形状，将第一个自由曲面上的离散点作为第二个自由曲面入射光线的起始点，所求第二个自由曲面上的离散点和照明面上对应的网格点即为出射光线，利用迭代计算公式即可得出第二个自由曲面上的点；将所得到的两个自由曲面上的点导入三维软件中建模，即可得到透镜模型。As shown in Figure 1 and Figure 2, the projection low beam consists of four parts, including a chip 1, an ellipsoid reflector cup 2, a baffle 3 capable of forming a 15° cut-off line, and a double free-form surface lens 4; as shown in Figure 3 and As shown in Fig. 4, the double free-form surface lens is composed of two free-form surfaces, the first free-form surface 41 and the second free-form surface 42, and a cylindrical side, both of which participate in the correction of the light angle, and the cylindrical side is convenient for fixing the lens on the bracket superior. As shown in Figure 5, it is the light distribution diagram after the light is emitted from the focal point. According to the national standard light distribution requirements and illuminance distribution, the area of the lighting surface is set as a semi-elliptical area centered on the center point of the lighting surface, and then the lighting The area is divided, and then according to the energy conservation, the relationship between the radius of each area and the angle of the outgoing light is obtained, the angle correction ratio of the two free-form surfaces is set, and the C value is calculated. According to the size of the C value and the angle of the outgoing light from the focal point and the illumination Surface correspondence, use the iterative calculation formula to calculate the shape of the first free-form surface, take the discrete point on the first free-form surface as the starting point of the incident light on the second free-form surface, and obtain The discrete points on the surface and the corresponding grid points on the lighting surface are the outgoing rays, and the points on the second free-form surface can be obtained by using the iterative calculation formula; the obtained points on the two free-form surfaces are imported into the 3D software to construct model, the lens model can be obtained.