Thermal-Structural Analysis for the Optimization of a Low Beam Projector Headlight Design

摘要

This paper is to demonstrate the application of modern Engineering Software to improve and advance the mechanical design processes of a low beam projector headlight. Nowadays, advanced finite element tools are able to run and coupled different physics modules to analyze complex geometries and their material combinations. The particular issue in this study is the light switching mechanism in a headlight structure design. During lighting, the jam of the low beam projector solenoid actuated pivot due to thermal expansions has been distressing the normal operation of the overall headlight structure. A comparison between the original and a new convection enhanced head lamp design is therefore scrutinized. For both cases, heat transfer analysis, where it was included natural convection, conduction, and radiation with a concentrated heat source are proposed in order to obtain the temperature distribution fields at the light switching mechanism. The results were used to run future structural stresses analyses where the average thermal expansion of the crankshaft mechanism was determined.