Headlight Lens Designed for Motorized Beam Shifting Systems

Today, there are more sophisticated motorized beam shifting systems that are very dependent upon the precision and transparency of the headlight lens. Although actuators and control modules get the most attention, the lens is key to ensuring the light is shaped, directed, and switched at low and high beam for optimal performance. Roughly designed lens will scatter light, break up the cut off line, which will nullify the purpose of an otherwise advanced adaptive lighting system.

Danyang Yeya Opto-Electronic Company Limited focuses on LED multifunctional lighting products, in which the LED lens is the key part to the performance. Here are four key considerations in designing headlights for motorized beam shifting use.

1. Optical Precision for Sharp Cutoff Lines

Motorized beam switchers utilize a beam shifting system or solenoid beam shift to switch between low and high beam. The lens will have to harmonize with this moving part to form a sharp horizontal cut-off line on low beam. Any imperfection in the surface, inconsistent curvature or optical distortion will cause oncoming cars to experience glare, while reducing the effectiveness of the light on the road.

The material used to make high quality lenses is designed with computer-optimized freeform optical surfaces, which collimate light from the LED source. Danyang Yeya adopts the advanced injection molding techniques to make sure every lens conforms to the strict geometric tolerances, producing a sharp, which conforms to either Europe or America standard specification, etc. This accuracy is critical for meeting ECE or DOT standards.

2. Thermal and Impact Resistance

Headlight lenses are one of the most exposed components of the vehicle that are exposed to vibration, road debris, UV radiation, and extreme temperatures. Other factors include the need for long-term dimensional stability and optical clarity of the lens material, when used with motorized beam shifting systems (which can increase stress from the actuator also).

It is the industry standard in terms of impact strength and thermal stability and is called a polycarbonate (PC). Danyang Yeya coated it with UV hard film to prevent turning yellow and cracking at the surface. This coating also creates scratch resistance, which means that after being exposed to rough luminous circumstance for a long time, the lens can still maintain the optical property. Material grades and coatings can be customized by us for customers who demand OEM or ODM solutions to performance requirements for durability.

3. Compatibility with Actuator and Shield Movement

Using motorized beam shifting systems adds moving parts AFTER the lens. The lens design must be such that optical interference will not be caused on the path of the cut-off shield or the roller shutter. This must be carefully coordinated with the size of the focal length, position of the shield, and shape of the lens.

Based on the order request, Danyang Yeya engineers conduct a close cooperation with customers to make sure the lens geometry have to satisfy the actuator stroke and the position of the shield respectively. From motorcycles to passenger vehicles to ATVs, whichever vehicle you're using, we modify the profile of the lens so the beam remains consistent all the way through the travel of the shield. It's this level of compatibility that makes a lighting system truly integrated, especially when compared to a bunch of mismatched pieces.

4. Custom Molding for OEM and ODM Projects

Size, mounting points and the beams on the individual housings all vary for the different types of housing systems. There are a large number of factory standard lenses on the market today which may not be the optimal size shape and quality. This is where fully custom mold designs, and tooling, from Danyang Yeya, based on existing molds, or new designs will become important.

We can produce a large number of lenses for a number of brands such as, BMW, Toyota, Ford, Honda, Porsche and motorcycle lenses such as, Vespa, Yamaha, etc, all of these will be engineered by professional engineers, or designed to meet your exact needs by our expert engineers. We have a rigorous quality control system that is applied at every step from the materials choice to the final inspection to ensure each and every lens meets your specific needs concerning clarity, fit and life time. We can assure you of a reasonable price, prompt production times and quick delivery.

Summary

The optical precision, thermal and impact resistance, mechanical compatibility and flexibility customization are the required properties of a headlight lens used in motorized beam shifting system. Danyang Yeya Opto-Electronic Company Limited fuses in these four elements coupled to quality first manufacturing and response service. We have the experience and expertise to offer our client-required OEM or ODM project carving lenses for automotive headlights, turn signals and other auxiliary lighting solutions for forklift trucks, trailers or anything else in between. Please give us a call to discuss your needs and to get samples.