Performance Analysis
VW ID3 headlamps construction and performance analysis
By Piseo —
For the first time ever, an independent, in-depth technical analysis that unveils how a tier-1 manufacturer takes advantage of LED technology
Key Features:
- Teardown of the VW ID3 headlamp
- Analysis of the general architecture of the headlamp
- Analysis of the architecture of the headlamp modules: optical, mechanical, assembly, electronics, thermal management
- Performance characterization
- Performance analysis
- Regulatory compliance
- Statement on product design and performance
Product objectives:
An in-depth and independent analysis:
- To provide automotive lighting market players with a deep understanding of the solutions that have been implemented in the analyzed device
- To show how those solutions contribute to the lighting performance and road users’ safety
- To highlight the key findings in relation to other state-of-the-art marketed products
Available on our Yole Group All-Inclusive Automotive Package
Table of contents
Introduction
Objectives of this report
Key findings
About PISÉO
About A2MAC1
PISÉO and A2MAC1 – team-up
VW ID3 headlight in-depth analysis: who does what?
Authors of this report
Glossary
Companies cited in this report
Varroc Engineering Limited – company profile
Analysis process
Executive summary
Description & analysis of the architecture
- General architecture
- ID3 headlamp
- Outer interfaces and installation
- General architecture
- Architecture
- Low beam – ADB module
- Bi-Matrix projection module
- Decorative illuminated surround
- DRL, TI & position module
- Light sources
- Light guides
- Front diffusers
- Extended-range module
- Extended-range HB
- Installation in the headlamp
- Extended-range HB – PCB
- Extended-range HB – collimators
- Cornering module
- Cornering beam
- Cornering module
- Cornering and extended range
- Light-off appearance
- Low beam & ADB module
- Extended-range and cornering modules’ appearance
- DRL and TI appearance
- Alignment process
- Assembly operations
- Decorative illuminated surround
- LB / ADB module
- DRL & TI
- All modules
- Assembly operations
- Electronic architecture
- Diversity of LED PCBs
- Low beam PCB
- DRL & TI indicator
- Cornering beam
- Range-extender module
- Decorative illuminated surround
- PCB LED architecture
- Headlamp controller
- Thermal management
- Thermal management overview
- Thermal management of lighting modules
- Low beam module
- High beam module
- Cornering module
- DRL & TI module
- Decorative low beam module
- Architecture - synthesis
Performance characterization
- Methodology for performance measurements
- Characterization setup
- Performance analysis methodology
- Low beam – performance measurements
- Performance
- Beam quality
- Road projection performance
- ADB – High beam performance measurements
- Performance
- ADB beam quality
- Comparison of high beam modes
- Road projection performance
- Overview
Regulation compliancy
-
- Performance evaluation – low beam
- ECE R112 regulation - low beam
- Performance evaluation – high beam
- ECE R112 regulation – high beam (ADB)
- ECE R112 regulation – high beam (ADB + extended range)
- Colorimetry in LB
- Performance measurement
Key findings
PISÉO presentation
A2MAC1 presentation
- Nichia
- OSRAM
- Varroc Lighting Systems
- Volkswagen
- Plastic Omnium
Objectives of the report based on PISÉO’s and A2MAC1’s collaboration
The integration of LED technologies has given automotive lighting manufacturers the opportunity for strong differentiation via new designs and functionalities. Automotive headlamps are subject to many technical and aesthetic considerations allowing multiple architectures and optical solutions. Therefore, OEMs and Tier1/2s are looking for accurate technical and performance insights of commercialized devices in order to consolidate their own product strategies.
PISÉO and A2MAC1 each provide unique complementary skills: PISÉO in LED-based system design and performance characterization, and A2MAC1 in automotive benchmarking. Given the complexity of a complete technical and performance analysis of a modern LED headlamp and A2MAC1’s long relationship with the automotive industry, the two companies collaborated to develop this report.
A2MAC1 provided access to the vehicle and set up the test, and PISÉO performed the technical and performance analysis of the headlamp.
Both companies are committed to providing the markets with the best possible benchmark data and insight into commercially available cutting-edge LED-based headlamps.
Key findings
The analyses of both the architecture and the photometric performance confirm a high-quality product.
Sophisticated optical solutions have been designed and implemented to meet strong performance and integration requirements.
The ID3 headlamp embeds an ADB function whereby 1 to 11 LEDs are selected to extend the beam and cover more than the low beam. However, the resolution of the lit areas, being limited to 11 LEDs, appears low compared to other ADB headlamps installed on high-range vehicles, but it is a step up for this function.
The optical devices of the ADB function are nicely designed ancd well assembled, resulting in good beam quality.
Chromatic effects have been noted along the cut-off line of the low beam. This is due to the technical solution, which generates the cut-off line being unable to suppress the chromatic effect entirely.
Electronic solutions are not fully optimized. The LED choice is valuable, but the implementation on the boards shows a considerable variation and a lack of optimization with basic process constraints.
Analysis process
PISÉO’s analysis process, as applied to the ID3 headlamp, is based on two distinct phases: a teardown and reverse engineering phase (optics, mechanics, assembly, electronics, thermal management analysis), and a performance characterization phase (characterization plan, headlamp control setup, measurements). Two identical products are used, one for each process phase.
Based on the cross analyses of the outcomes of these two phases, PISÉO has provided a comprehensive statement on the design and performance of the headlamp.
