Free-form matrix lens empowerment: Achieving megapixel ADB and iconic lighting effects

                                                    Free-form matrix lens empowerment: Achieving megapixel ADB and iconic lighting effects


1. Background and Challenges:

The brand plans to equip its flagship electric SUV with the most advanced digital lighting system, aiming to create industry-leading lighting performance and a unique brand visual identity.
Key challenges:
It is necessary to achieve high-resolution adaptive high beams, providing the ultimate anti-glare effect and potential for road information projection.
Integrate complex optical systems and powerful thermal management within the compact headlight space.
Ensure that the near-light type perfectly complies with the world's most stringent regulations (such as the European standard ECE R149, the Chinese standard GB, etc.).
Create unique and recognizable daytime running lights and dynamic light language effects.
The power consumption of the system needs to be optimized to meet the range requirements of electric vehicles.


2. Solutions and Technologies:

Core technology: Matrix lighting modules based on high-precision microstructure freeform surface lenses are adopted.
Key design highlights:
Megapixel-level zoning: A single lens module in combination with a high-density LED array can independently control thousands or even tens of thousands of tiny lighting zones.
Precision optical path design: The free-form surface lens precisely guides each beam of light, forming sharp and clear cut-off lines and highly uniform near light spots, and provides precise zone control capabilities for ADB.
Integrated light guide technology: Integrate light guide strips at the edge of the lens or in specific areas to achieve fine, continuous and dynamic DRL and turn signal effects.
Efficient thermal management collaboration: The selection of lens materials (such as high-temperature resistant PMMA or glass) is closely coordinated with the design of the heat dissipation substrate and shell to ensure long-term stable light efficiency.
Intelligent control interface: Deeply integrated with on-board cameras and domain controllers to achieve real-time dynamic lighting based on road conditions.


3. Achieved effects and advantages:

Revolutionary ADB performance:
Achieve up to more than 1.3 million independently controllable pixels.
It can precisely mask multiple targets (vehicles, pedestrians, road signs), with a mask response time of less than 50ms.
While ensuring that the maximum high beam illumination distance in the unshaded area is greater than 600 meters, completely eliminate the glare for oncoming/same-direction drivers.
(Attached: Nighttime Road Test comparison Chart - Traditional High Beam vs. ADB Enabled)
Outstanding basic lighting:
The uniformity of low beam is greater than 0.6 (far exceeding the regulatory requirements), the illuminance of B50L is greater than 25 lx, and that of E3 is greater than 3 lx.
The low beam width has been increased by 20%, significantly improving the field of vision at curves and intersections.
(Attached: Low light/high light pattern diagram and illuminance distribution diagram)
Stunning visuals and functionality:
Realize smooth dynamic welcome light language and lane guidance projection functions.
Create a highly recognizable three-dimensional DRL lighting effect, which has become a signature design element of the [brand].
(Attached: daytime DRL effect diagram, dynamic light language video /GIF)
High efficiency and reliability:
The luminous efficacy of the system is > 80 lm/W, which is 15% higher than that of the traditional reflective scheme, optimizing energy consumption.
The lens assembly has passed rigorous durability tests (high temperature and high humidity, thermal shock, UV aging), ensuring a service life of more than 15 years.
Regulations and Space:
Pass the European standard ECE R149 ADB certification and the national standard GB and other target market regulations at one time.
The compact optical design meets the extremely thin styling requirements of the front face of the [model].

4. Customer Value and Project Outcomes:
      The headlight system of [model] has become one of the core highlights of its high-end positioning, earning wide acclaim from global automotive media and consumers and being hailed as "the benchmark of lighting technology".
      This advanced lighting system significantly enhances the safety and driving experience of night driving, becoming an important configuration that attracts users to make a purchase.
The project was successfully mass-produced on schedule, meeting the high-quality requirements of [brand] 's flagship model and consolidating [Brand]' s image as an innovative leader in the automotive lighting field.
     This application fully demonstrates the great potential and value of freeform surface matrix lens technology in achieving intelligent, safe, personalized and efficient vehicle lighting, laying the foundation for future higher-level intelligent lighting (such as high-definition projection interaction).