Prior to 1990, standard automotive headlamp assemblies contained only incandescent light sources and were mostly independent to create all the functions required. Whether these functions are created by sealed beam lights or by bulbs, reflectors, and optical assemblies, they all operate in a similar manner. The light mode is static and is primarily defined by the reflector and optics. The supported standard lighting modes are high beam, low beam, turn signal, position light and fog light modes. For decades, these features have only provided the basic light distribution options needed to drive safely in most situations.
In the early 1990s, a new source of high-intensity discharge (HID) emerged. This power supply produces more efficient, brighter lighting and supports low beam and high beam functions. However, after the transition to HID, a simple battery connection was not enough to control the lights. In contrast, HID sources require advanced power electronics to convert the DC battery voltage source into a resonant AC power source that properly regulates the light output.
This change brings design that once involved only mechanical and optical systems to the design of advanced electronics designers. Over the next 20 years, the HID system was further improved by engineers into a cost-effective solution for simultaneous high beam/low beam functions. . However, it still does not have more advanced lighting features because a single light source is subject to a fixed size.
In 2007, the first light-emitting diode ( LED )-based headlamps were used in new cars. LED-based systems give designers greater flexibility because of their extremely small light source. Of course, the adjustment of the LED also depends on the conversion of a certain power supply. In particular, LED drivers are indispensable for converting battery voltage sources into constant current drive sources suitable for series or series/parallel LED arrays.
Similar to HID electronics, LED drivers also increase the cost and complexity of automotive headlamp systems. Despite this, the inherent size of the LED driver is reduced, the controllability of the intensity and color is significantly improved, and the efficiency is also improved. The benefit to car manufacturers is that the system has been improved to be more suitable for sale. In addition, designers can take advantage of the aesthetically pleasing and innovative form factor that also creates effective brand recognition for automakers.
Throughout the past eight years, LED car headlights have evolved from a single LED function option, such as daytime running lights (DRL) or fog lights, to a complete LED headlamp system that is versatile. Today, most mid- to high-end cars have a fully LED-based car headlight option. Now let's take a closer look at the LED car headlight system.
LED car headlight architecture
Due to the inherent power levels of the associated components, LED automotive headlamp assemblies are typically designed as a single stage switch mode power supply. In general, buck-boost topologies are preferred for providing regulation during load dump and cold start. During a load dump, the battery voltage may rise to 60V (and sometimes even higher); during cold start, the battery voltage may drop to 4.5V or even lower! At any extreme input condition, the buck-boost converter can regulate the output current to the LED string (total forward voltage above or below the battery voltage).
1. This typical automotive headlamp system implements a single stage power architecture in which each converter can adjust a different function in the system.
A complete front lighting system often consists of multiple converters, each of which is responsible for adjusting different parts of the system (Figure 1). Each car headlight function is typically supported by a separate LED string. Usually only DRL and position lights are multiplexed into one string. In this case, the position lamp is created by dimming the DRL string with a duty cycle of about 10% by a pulse width modulation (PWM) function.
Most existing LED automotive headlamps have two basic electronic components: an array of LEDs in the headlights of the car, along with associated optical and mechanical components, and a lighting control unit that is typically externally connected within the weather-resistant enclosure ( LCU). The LCU printed circuit board (PCB) contains power converters such as current regulators and microprocessors and transceivers that can communicate with other electronic control units (ECUs) in the system. A body control unit (BCU) located near the cockpit sends commands to the LCU to manage all body functions in the car.
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