Jinbo (蔣金波) Jiang

Design and fabrication of freeform reflector for automotive headlamp

Modern automotive illumination systems require higher efficiency, safety, and good aesthetic features. The design, fabrication and measurement are critical issues for automotive illumination systems. The non-imaging optical design for the automotive lighting system, which departs from the methods of traditional optical design, is an arisen interdisciplinary field. In order to meet the traffic regulations, unique freeform shapes and geometries should be adopted to create the special legal light pattern. Mean while, high accuracy freeform reflector could not be made by conventional manufacturing process, ultra-precision machining is the method. And the measurement of the freeform surface is also a new area. In this paper, the optical design, fabrication and the measurement of the freeform reflector headlamps are investigated.

Integrated manufacturing technology for design, machining and measurement of freeform optics

Ultra-precision machining technology plays an important role in the manufacture of advanced freeform optics. An integrated manufacturing platform is developed to cover freeform optics design,CAD continuous data transform,freeform model re-construction,simulation and cutting optimization of multi-axis machining,compensation of machining errors,and the measurement and characterization of freeform surfaces. The adoption of the platform technology shortens the time to develop complex NC programs for different multi-axis machine tools to manufacture different types of freeform optics. This system helps to avoid expensive repeated cutting tests,as well as to improve the surface quality of freeform products. The stability and effectiveness of the proposed integrated platform are verified through a series of tests.