LED路灯透镜的光学设计及制作工艺研究

发布时间：2019-03-30 15:16

【摘要】：当今照明行业对于道路灯具的设计要求越来越高,所设计透镜的配光不仅要满足《城市道路照明设计标准》和《道路照明灯具节能认证技术要求》中的要求,且在原有的道路基础上要实现其道路亮度总均值、纵向亮度均匀值、照度总均匀度等的不断提高,使其对行人和车辆驾驶员的眩光值降低,以此来提高道路安全系数,减少因道路照明所引起的事故。目前国内已经有很多的LED路灯,但是其运用的道路杆距比(相邻两灯具距离与杆高的比值)为3.2、3.5、3.6、3.8、4.0等,限制了道路灯具的排布,增大了道路照明成本。因此需要对光学透镜进行新型设计来拓展道路照明技术的应用范围,进一步提高LED道路照明的水平,降低道路照明建设的成本。为了提高LED路灯透镜照明的质量且降低道路照明成本,本文研究了杆距比为4.2的LED路灯透镜的设计方案。依据LED光源发光原理、非成像光学理论和道路照明要求标准,研究设计透镜的偏微分方程求解法和试错法,利用两种方法分别设计了适用四车道、六车道照明的LED路灯,并根据整体方案对光学系统的光路进行仿真模拟,针对模拟结果进行分析。试错法,即通过建模、光线追迹、场景模拟等分析结构,若模拟结果不符合道路照明要求,分析出现问题的原因,对所建模型进行点坐标的试错修改,最终得到符合要求的光斑、配光及场景模拟结果。偏微分方程求解法,即根据斯涅耳定律,边缘光线原理等建立初始的微分方程组,运用MATLAB编程解出微分方程组的数值解,把得到的自由曲面上的离散点数据导入Solidworks中建模、模型导入Tracepro软件进行光线追迹,并在DIAlux进行场景模拟,确定了最终的结构。本文主要研究了LED路灯透镜的光学设计及模具设计的方法、模具材料的选用和加工工艺、注塑加工材料以及其流程。运用两种不同方法设计得到两款透镜分别用于四车道和六车道照明;并且四车道透镜的U0达到0.64、UI 0.78、TI 8、SR 0.53、Ehav 0.565、CU大于0.75;六车道透镜的U0达到0.60、UI 0.76、TI 9、SR 0.78、Ehav 0.650、CU为0.60;均实现了杆距比为4.2的照明目的。使用热流道模具加工生产,获得无水口料的透镜,并对其产品性能进行了实际测试,得到透镜的光强曲线分布均满足要求,验证了设计的正确性。使得同等100 km的道路照明,相对于安装杆距比4.0路灯可节约120余盏灯具,大大降低了道路的照明成本。
[Abstract]:Nowadays, the lighting industry has higher and higher requirements for the design of road lamps and lanterns. The designed lens should not only meet the requirements of "Standard for Urban Road Lighting Design" and "Technical requirements for Energy Saving Certification of Road Lighting Lamps". On the basis of the original road, it is necessary to realize the continuous improvement of the total luminance average value, the longitudinal luminance uniform value and the total illumination uniformity value, so as to reduce the glare value to the pedestrians and vehicle drivers, so as to improve the road safety factor. Reduce accidents caused by road lighting. At present, there are a lot of LED street lamps in China, but the ratio of distance to height of two adjacent lamps is 3.2, 3.5, 3.6, 3.8, 4.0, etc., which limits the arrangement of road lamps and increases the cost of road lighting. Therefore, it is necessary to design a new type of optical lens to expand the application of road lighting technology, further improve the level of LED road lighting, and reduce the cost of road lighting construction. In order to improve the lighting quality of LED street lamp lens and reduce the cost of road lighting, the design scheme of LED street lamp lens with rod distance ratio of 4.2 is studied in this paper. According to the principle of LED light source, the theory of non-imaging optics and the requirement standard of road lighting, the solution of partial differential equation and the trial and error method of designing lens are studied. Using the two methods, the four-lane and six-lane LED street lamps are designed, respectively, which are suitable for four-lane and six-lane lighting. According to the whole scheme, the optical path of the optical system is simulated and the simulation results are analyzed. Trial and error method, that is, through modeling, ray tracing, scene simulation and other analysis structures, if the simulation results do not meet the requirements of road lighting, analyze the cause of the problems, and modify the point coordinates of the model. Finally, the results of light spot, light distribution and scene simulation are obtained. The solution of partial differential equation is that the initial differential equations are established according to Snell's law and edge ray principle, the numerical solution of differential equations is solved by MATLAB programming, and the data of discrete points on free-form surface is imported into Solidworks for modeling. The model is imported into Tracepro software for ray tracing, and the scene is simulated in DIAlux to determine the final structure. In this paper, the optical design and mold design method of LED street lamp lens, the selection and processing technology of mould material, injection molding material and its flow chart are studied. Using two different methods, two lenses were designed for four-lane and six-lane lighting, and the U _ 0 of four-lane lens was 0.64, UI 0.78, TI-8, SR 0.53, Ehav 0.565, CU greater than 0.75, and U0 of four-lane lens was 0.64, UI 0.78, TI-8, SR 0.53, Ehav 0.565. The U0 of the six-lane lens is 0.60, UI 0.76, TI 9, SR 0.78, Ehav 0.650 and CU 0.60. The lens of anhydrous port material was obtained by using hot runner mould, and the product performance was tested. The light intensity curve distribution of the lens met the requirements, and the correctness of the design was verified. The road lighting of the same 100 km can save more than 120 lamps compared with the installation pole distance ratio of 4.0 street lamps, which greatly reduces the lighting cost of the road.
【学位授予单位】：江苏大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TM923.34

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