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Ownership

Form Factor DRI

Contributors

Project DRI

Adrian Au

Steven Poung

Adrian Au

Research

 Reference images

Notes:

Illuminated “light strips” from audi concept Q7

Tesla model X

Lightyear One

Tesla Model 3 Teardown

High-Level Lighting Layout Concept

Design Considerations

Try to maximize the amount of design re-use between all the various lighting locations. This includes maintaining similar construction techniques, PCB designs, LED spacing/pitch, etc. in order to make our lives easier.

Terminology

In regards to PCB dimensions:

Dimension

LED Pitch

  • Constant for all light elements

  • A spacing of ~8 mm between each LED should help to facilitate better diffusion/minimize LED “hotspots” (https://www.waveformlighting.com/led-strip-lights)

  • High Density LED strips use 120 LEDs per meter (8.3 mm pitch)

  • Medium Density use 72 LEDs per meter (13.9 mm pitch)

  • Low Density use 30 LEDs per meter (33.3 mm pitch)

PCB Length

  • Determined by desired light element length (number of LEDs), LED pitch, heat sync length requirements, and mounting hole locations

  • Constrained by amount of available space on either side of the light element

PCB Width

  • Determined by width requirements for heat sync and/or connector

  • Constrained by amount of available space above/below the light element

PCB Depth

  • Determined by depth requirements for heat sync and/or connector

  • Constrained by available space behind the light element

Form Factor Concepting

Headlights

Screenshots

High-level headlight architecture consists of thermoformed polycarbonate lens mounting to the flanges on the front of the aerobody. Headlight housing (material tbd) will be mounted to the rear of the aerobody panel (mounting method tbd). Light diffusion elements for DRL and turn signal to be housed inside the headlight housing. Electronics to be housed inside housing/on rear of housing.

Tail Lights (Rear Brake Lights and Rear Turn Signals)

 Tail light Arrangement Concepting

High Mounted Brake Light and BPS Fault Indicator

As per the ASC regulations, the high mounted brake light and BPS fault indicator will live in the same relative vicinity, sharing the same viewing angles (30° from center in both directions and 15° up from horizontal).

Screenshots of Proposed Layout:

The LEDs for the high mounted brake light and for the BPS fault indicator will live on the same PCB. The LEDs should be located as close as possible to the top edge of the board. This will allow us to maximize the viewable angle of the LED by placing it as close as possible to the outer surface of the car (prior to accounting for light diffusion material).

Dimension

Value

Notes

Light Element Size

  • 95mm x 13mm for Brake Light

  • 8mm x 8mm for BPS Fault Indicator

  • Don’t expect nor require entire specified area to be uniformly illuminated to regulation brightness

LED Pitch

  • 12mm

  • Constant for all light boards

  • Spacing between Brake Light LEDs and BPS Fault LED is also 12mm

Number of LEDs

  • 8 LEDs for Brake Light

  • 1 LED for BPS Fault Indicator

Max PCB Size

(Length x Width x Depth)

  • 150mm x 10mm x 25mm

  • Max depth includes height off all components (i.e LEDs, heat sync)

  • LEDs should be located as close as possible to top edge of board

  • All dimensions negotiable

References

Electrical Page: MSXIV High Mounted Brake Light

Array Layout Page: Final Array Layout

File links or locations

Design Journal

Date (YYYY-MM-DD)

Notes

2020-05-25

Layed-out initial CAD model architecture:

  • Headlight Lens to be thermoformed polycarbonate and will be glued and fit to aerobody flanges (side panel, hood, panel, bottom panel)

  • Headlight Housing to be 3D printed in sections (relatively large part) and will be fastened or glued to interior of aerobody

2020-06-05

Took screenshots of CAD and added to confluence. Came to conclusion that headlight has the potential to be really big (see poorly dimensioned “drawing”). Will need to determine what maximum feasible size of lighting elements are for DRL and front turn signal

2020-06-06

  • #LightingTaskforce meeting liked the “non-bulby” look.

  • A common theme between “boring” headlights: looks too bulby. lol.

  • Follow-up to investigate feasibility.

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