Design modelling and simulation of aiming damping bracket for 2-wheeler lighting head lamp

Abstract

Design modelling and simulation of aiming damping bracket for 2-wheeler lighting head lamp to absorb vibration coming from road and helping to increase 1st natural frequency of aiming mechanism which results in increasing the stiffness of head lamp aiming mechanism.Current design of Head lamp (with one aiming screw and two pivot bush) is failing in CAE vibration analysis for 15 g constant acceleration for frequency range of 20 Hz to 500 Hz in all direction. First natural frequency of head lamp is 104 Hz which is very less to sustain 15 g acceleration and causes rattling and mechanical failure on internal aiming assembly component. Considering all constraints in head lamp design It is very difficult to increase first natural frequency of product more than 140 Hz, so designed plastic damper (Material - Nylon) in such way that damper can restrict swing movement of aiming assembly while vibration with fulfilling head lamp aiming function requirement of 4 degree up and down. With addition of Nylon damper head lamp frequency crosses more than 147 Hz without changing in current design and aiming concept and product is now passed in vibration CAE analysis and physical testing also.Performed physical testing of head lamp for 15 g acceleration at center of lens for 20 Hz to 500 Hz in all direction and observed no mechanical failure. Also validated testing result of head lamp with physical testing and CAE analysis and observed good correlation. In this paper would discuss design aspects, CAE, and proto validation of automotive head lamp.