Technology with Vision. Lighting the Future STANDARD AUTOMOTIVE BULBS

Transcription

1 Technology with Vision Lighting the Future STANDARD AUTOMOTIVE BULBS

2 BULBS and High Performance Light Up with is a globally positioned company with 70 locations in more than 30 countries. As a key innovation driver, we have been developing and manufacturing lighting, electric and electronic components and systems for the automotive industry for more than 100 years. ranks among the top 50 automotive suppliers globally and operates one of the world s largest aftermarket organizations for automotive parts, accessories, diagnostics and services. Our customers include all leading vehicle and system manufacturers, as well as the automotive aftermarket. The brand is synonymous with proven quality and cutting-edge automotive technology. The basis behind s success lies in its constant pursuit of innovations and design improvements and constantly creating value to the future of motor vehicles. As a leading partner of top vehicle manufacturers, is committed to state-of-the-art quality products and making the roads safer for drivers.

3 CONTENTS LIGHTING FUNDAMENTALS Basic Lighting Terms Tested Quality Lighting the Future Automotive s Halogen - Main Components Life Expectancy of a High Intensity Discharge Capsules (HID) - Main Components BULB SUMMARY Halogen Overview HALOGEN BULBS XENON CAPSULES MINIATURE BULBS INSTRUMENT PANEL BULBS

4 4 LIGHTING FUNDAMENTALS LIGHTING FUNDAMENTALS When it comes to driving safety, sight is the most important sense. Visibility can be impaired under various circumstances and driving under these adverse conditions will increase the risk of an accident. To meet these challenges, is continually improving existing lighting systems and developing new lighting equipment and components. basic lighting terms Vehicle lighting is becoming more complex all the time, but in all cases, the light source is central to the function of the lamp. With this in mind, below are the most important basic terms in lighting technology and the respective units of measure for bulb and light evaluation Luminous flux, Φ Unit: Lumen [lm] Luminous flux is the term used to describe the complete light output radiated from a light source. Luminous intensity, I Unit: Candela [cd] Luminous intensity is the part of the luminous flux which radiates in a certain direction. Illuminance, E Unit: Lux [lx] Illuminance specifies the ratio of the impinging luminous flux to the illuminated surface. Illuminance is 1 lx when a luminous flux of 1 lm impinges an area of 1 m K Light output, ŋ Unit: Lumen per [lm/w] Light output specifies the rate of efficiency with which the consumed electrical power is transformed into light. Luminance, L Unit: Candela per square meter [cd/m2] Luminance is the impression of brightness the eye has from a luminous or illuminated surface. Color temperature, K Unit: Kelvin [K] Color temperature is a measurement in degrees Kelvin that indicates the hue of a specific type of light. The color temperature of daylight is 6,000 K. LUMINOUS INTENSITY LIFE Light sources Light sources are radiators of temperatures which produce light through heat energy. This means, the more a light source is heated up, the higher its luminous intensity will be, but the shorter its life will be. Common light sources in the automotive industry are: Incandescent bulbs, Halogen bulbs, Gas Discharge (Xenon) lamps, and LED lamps.

5 LIGHTING FUNDAMENTALS 5 TESTED QUALITY All bulbs undergo painstaking tests to insure that the lamps that we deliver to our customers meet or exceed the requirements established by s Quality Assurance engineers. Headlight bulbs, for example, are scrutinized by our engineers for their light distribution properties using state of the art light measuring equipment: vibration and shock tests in line with IEC requirements, geometric measurements, light flux and power measurements as well as service life tests. Below are just some of the tests that our Quality Assurance department performs. Geometrical Measurement A measuring projector is used to check the filament geometry - with regard to the statutory standards in accordance with IEC The filament must be dimensioned and positioned within the bulb as specified in the standard. This is the only way to achieve optimum headlight power and prevent glare to oncoming traffic. Vibration and Shock Test Here, vibration resistance of the bulb and the filament in particular, is tested on an electro-dynamic vibration table. Paint Adhesion Test The adhesion of paint on colored glass bulbs such as the PY21W for example is tested in a climate chamber at different temperatures and air humidities. Optimum adhesion of glass bulb paint guarantees the prescribed amber indicator light over the whole service life period. Life Test Sophisticated tests are used to prove the high reliability of the bulbs over a long period. Light Flux Measurement The Ulbricht sphere and goniometer are used to determine the light fluxes and luminous intensities of the bulbs. This guarantees optimum light output of the bulbs.

6 6 LIGHTING FUNDAMENTALS LIGHTING THE FUTURE As a technological leader in the field of intelligent light distribution, (be it halogen, xenon or full-led headlights) and as a partner to renowned international vehicle manufacturers, always fulfills the highest expectations in product quality and performance. A bulb range benchmark is: top technology with no compromise in quality, founded on rigorous testing. This means optimum visibility thanks to top light quality and minimum failure rates thanks to durable and long lasting products. STANDARD AUTOMOTIVE BULBS FUNCTION The lighting system of a motor vehicle consists of lighting and signaling devices mounted or integrated to the front, sides, rear, and in some cases the top of the motor vehicle. The purpose of this system is to provide illumination for the driver to operate the vehicle safely after dark, as well as to increase vehicle visibility within its environment. Automotive lighting alerts other drivers to the vehicle s presence, position, size, direction of travel and driver s intentions regarding direction and speed of travel. A bulb can be considered as a replacement part with a limited service life. Yet, the bulb is part of the lighting system. It is an active component of a unit where all the elements should be perfectly matched to one another. Color temperature Color temperature is a measurement in degrees Kelvin ( K) that indicates the hue of a specific type of light source. Color temperatures over 4000 K are called cool colors (blueish white), while lower color temperatures ( K) are called warm colors (yellowish white through red). The higher the temperature of a light source is, the greater the proportion of blue and the lower the proportion of red in the color spectrum. An incandescent light bulb has a warm white color temperature of approximately 2700 K, while a High Intensity Discharge lamp has a cool bluish temperature of approximately 4,200 K. The illustration below provides an indication of the color temperature spectrum. Halogen 3200K Xenon Lamp HID (High Intensity Discharge Lamps) 4200K 1800K 4000K 6000K 7000K 10000K High performance bulbs Daylight INCANDESCENT BULBS Incandescent bulbs (vacuum bulbs) are thermal radiators, since the tungsten filament is made to glow by the addition of electrical energy. In general, the light output of a standard bulb is low. Additionally, evaporated tungsten particles considerably blacken the bulb and reduce all lighting values as well as service life. HALOGEN BULBS By adding small amounts of halogen atoms such as iodine, a halogen bulb can be operated at higher temperatures, thus increasing the light output of the bulb. This process is known as the cyclic process Not only does this process improve the efficiency of the bulb with the same useful life, the bulb does not blacken like an incandescent bulb. There are basically two different types of halogen bulbs available: single filament and double filament. The types H1, H3, H7, H9, H11, HB3/9005 and HB4/9006 only have one filament. These bulbs are used for either low beam or high beam application. In comparison to H1 bulbs, H7 bulbs have a higher luminance, lower power consumption and better light quality. The second type of halogen bulb has two filaments, one for low beam and one for high beam. These types are H4, HB1/9004, HB2/9003, and HB5/9007.

7 LIGHTING FUNDAMENTALS 7 HALOGEN BULB - MAIN COMPONENTS Filament for low beam Filament for high beam AntACiglare Gas composition and adapted pressure Shield Lamp UV cut quartz glass with optical coating Terminal Stainless steel H4 Type CYCLIC PROCESS INSIDE A HALOGEN BULB The tungsten filament is made to glow by the addition of electrical energy. This leads to metal evaporating from the filament. Thanks to a halogen filling (iodine or bromine) in the light, the filament temperatures increase to almost the melting point of tungsten (approximately 6,152 F / 3,400 C). This results in high light output. In the direct vicinity of the hot bulb wall, the evaporated tungsten combines with the filling gas to form a translucent gas (tungsten halide). If the gas approaches the filament again, it breaks down due to the high filament temperature and forms a homogenous tungsten layer. To keep this cycle going, the outer temperature of the light bulb has to be 572 F / 300 C. To achieve this, the quartz glass bulb must fit closely around the filament. The gas composition in the bulb is critical to the light output. The addition of small amounts of inert gases such as xenon reduces heat dissipation from the filament. In addition, a higher filling pressure can be used, thus combating tungsten evaporation. 1 Tungsten filament Halogen filling (iodine or bromine) 3 Evaporated tungsten 1 4 Tungsten halide 3 5 Tungsten deposits

8 8 LIGHTING FUNDAMENTALS LIFE EXPECTANCY OF A BULB Service life and light efficiency, among other things, strongly depend on the supply voltage used ,2 V LIFE EXPECTANCE DEPENDENT ON VOLTAGE Therefore, protective resistors are used in some vehicle types to ensure that the supply voltage doesn t exceed 13.2 V. On the other hand, undervoltage, e.g. due to a defective generator, means exactly the opposite. The light now has a considerably higher red fraction and thus light efficiency is lower. Rule of thumb: If the supply voltage of a bulb is increased by 5%, then the luminous flux increases by 20%, but at the same time service life is halved. Lifetime in % ,2 V 13,2 V age increase in % HIGH INTENSITY DISCHARGE CAPSULES (HID) MAIN COMPONENTS Return pole with ceramic tube Crown Fastening cams Outer bulb Tungsten electrodes Antiglare Discharge chamber with filling Contact ring Collar Luminance cd / cm 2 D2R (HID) FUNCTION High-intensity gas discharge (HID) headlamps use the physical principle of electric discharge to produce light with an electric arc rather than a glowing filament. The chamber between the electrodes is filled with the inert gas, xenon, and a mixture of metals and metal halides. The electronic ballast applies a controlled ignition voltage to the gas in the chamber and the gas is ionized and made to glow with the aid of a light arc. The lamp only achieves its full brightness after a few seconds when all the components have been ionized. Once the full light output has been reached, a ballast regulates the operating voltage necessary to keep up the physical process. HID bulbs produce more light for a given level of power consumption than ordinary tungsten and tungsten-halogen bulbs. Because of the increased amounts of light available from HID bulbs relative to halogen bulbs, HID headlamps producing a given beam pattern can be made smaller than halogen headlamps producing a comparable beam pattern.

9 LIGHTING FUNDAMENTALS 9 Typical light distribution and color temperature of a light beam with standard halogen bulb. Typical light distribution and color temperature of a light beam with HID capsule. Light source Luminous flux Luminous intensity Halogen bulb (H1) Filament 1550 lm 1450 cd/m 2 Gas discharge lamp (Xenon D1S) Light arc 3200 lm 3000 cd/m 2 Capacity Energy balance Service life Vibration-proof Ignition voltage Electronic control Kelvin Temperature (Daylight ± 6000 K) 55 W 8 % light radiation 92 % heat radiation approx. 500 h to a certain extent no no 3200 K 35 W 28 % light radiation 58 % heat radiation 14 % UV radiation 2,500 h yes yes 23,000 V (3rd generation) yes 4150 K (Projection system) Gas Discharge lamps are categorized according to their respective development version: D1, D2, D3 and D4. While all are discharge lamps (D), there are some major differences between the generations. Due to the different electrical parameters, it is important to match the gas discharge lamp with the appropriate ballast unit. For instance, the D3 and D4 lamps cannot be used with the control units for the D1 or D2 lamps.

10 10 s Summary Headlight and Fog Light STANDARD BULBS Front Indicator Rear Indicator INDICATOR LIGHT /SIDE MARKER P21W PY21W P27W P27/7W H21W Low Beam High Beam Fog Light XENON (HID) D1S D2S D2R WY5W W21W WY21W, K W5W H1 HALOGEN H2 H3 H4 LICENSE PLATE LIGHT T4W W3W C5W TAIL / PARK LIGHT P21/4W P21/5W R5W H7 H8 H9 H R5W R10W, M W21W W21/5W R10W H11 HB1 9004/HB1 HB2 9003/HB2 HB3 9005/HB3 HB4 9006/HB4 HB5 9007/HB5 H13 R2 INTERIOR LIGHT H6W R5W R10W C5W, M STOP LIGHT / REAR FOG LIGHT / REVERSE LIGHT P21W P21/4W P27W W16W W21W, K NOTE Passenger Car 12V Heavy Duty 24V P21/5W

11 s summary 11 HALOGEN BULB OVERVIEW High Performance Xenon Blue Description OEM quality replacement bulbs Xenon-look light with a color temperature of 4200 K Xenon-look light with a color temperature of 4200 K Yellow light for high contrast in extreme weather age x x x x High age x x x x Range Heavy Duty x x 12V x x x x 24V x Regulations /ECE/ / Only Only Color Yellow Single Box x Package Twin Blister Pack x Twin Hard Plastic Case x x

12 12 Halogen bulbs H1 H3 P14.5s T2.5 PK22s T Yellow High age High age ECE R37 H1 H1LL H H H H1 100W H H1 130W H1 24V Yellow High age High age ECE R37 H3 35W H3 H H H H3 100W H H H3 130W H3 24V H Heavy Duty High age H3 24V HD H3 24V 100W X511 T3 H3C H2 G4 T High age H2 100W H Yellow H H

13 halogen bulbs 13 H4 H7 P45t T4.625 PX26d T /55 H4 P45T H7 H7LL H4 P43t T Yellow High age Hella H H H H7 70W 12 35/ / /55 ECE R37 H4 35/35W H4 45/45W H High age ECE R37 H7 100W H H H7 24V 12 60/ / /55 Yellow H H H H /80 High age H4 100/80W PGJ19-1 T / / / / /70W /90 High age ECE R37 Heavy Duty High age H H H4 130/90W H4 24V H4 24V HD H4 24V 100/90W Yellow H8 H H H

14 14 Halogen bulbs H9 H11 PGJ19-5 T4 PGJ19-2 T Yellow H9 H H H Yellow H11 H H H H H10/9145 H12/9055 PZ20d T4 PY20d T ECE R37 H10 H H13/9008 Suitability ECE R37 Light Color H Yellow H P26.4t T H /55 Suitability Light Color H /55 H /55 H /55 Extreme Yellow Yellow H /80 H

15 halogen bulbs 15 H16/ /HB1 PS24W T4 P29t T Suitability Light Color Yellow H H H / / /45 Suitability Light Color LL H /HB2 P43t T / / /80 High age Yellow H H /80W 12 60/55 Suitability Light Color / /80 H H /55 H /HB / / /80 Yellow H H H P20d T /80 H LL H H Yellow H High age W H H

16 16 Halogen bulbs 9005XS 9006XS P20d Straight T Suitability Light Color 9005XS H H P22d Straight T Suitability Light Color Yellow 9006XS H H H /HB4 P22d T4 9007/HB Yellow High age LL H H H W H H P29t T / / / / / / / /80 Yellow High age LL H H H /80W H H

17 halogen bulbs 17 HS1 800 Series PX43t T / Series Suitability ECE R37 Light Color HS1 PGJ13 T ECE R37 Yellow H H PG13 T Series Suitability ECE R37 Light Color Yellow Yellow H H H H Series PGJ13 T Suitability Light Color PG13 T Suitability Light Color Series G4 T Suitability Light Color 891

18 18 XENON CAPSULES / MINATURE BULBS D1S BA15d PK32d2 T3 BA15d B / /24 35 D1S D2R BA15d G6 P32d3 T D2R BA15d S8 D2S 12 17/8 12 P32d2 T D2S

19 MINATURE BULBS 19 BA15s BA15s BA15s B6 BA15s S LL Amber 7506NA Heavy Duty 5637HD LL BA15s B Amber 1156NA V LL BA15s G6 BA20d BA20d B / / /

20 20 MINATURE BULBS BA7s BA9s BA7s T2 BA9s T BA9s BA9s G3.5 BA9s T Halogen H5W Halogen H20W BA9s T3.25 BA9s G

21 MINATURE BULBS 21 BAX9s BAY15d BAX9s T2.75 BAY15d S Halogen H6W 12 21/ BAY9s 12 23/ / /7 Amber A 2057 BAY9s T /7 2057LL 12 27/7 Amber 2057NA Halogen H21W 12 27/7 / Amber 2057NALL 12 27/ BAU15s 12 27/8 Amber 1157NA 12 27/8 1157LL BAU15s S /8 / Amber 1157NALL 12 29/ /8 2357LL Amber /8 Amber 2357NA Amber 7510LTS 12 29/10 Heavy Duty 198HD 24 21/5 7537

22 22 MINATURE BULBS BAZ15d SV7-8 BAZ15d S8 SV7-8 T /4 Amber x29mm 6428 G x29mm DE3022 G4 T x29mm 8x29mm Halogen JC5 SV Halogen JC20 SV8.5-8 T3.25 P45t x31mm DE3175 P45t S13 SV8.5-8 T / / x35mm 6418 PX15d x35mm 6423 PX15d T6 SV8.5-8 T /25 A x41mm /25 A3603

23 MINATURE BULBS 23 SV8.5-8 W2.1x4.9d SV8.5-8 T3.25 SV8.5-8 T x41mm x41mm x41mm 6429 W2.1x9.5d SV8.5-8 T3.25 W2.1x9.5d T x37mm DE cp 2 cp SV8.5-8 T Amber 158A x41mm Blue 194B x41mm Green 194G 12 4 NA 194NA 12 4 Red 194R SV8.5-8 T Blue 2825BL 12 5 Amber 2827NA x44mm ECE version

24 24 MINATURE BULBS W2.1x9.5d W2x4.6d W2.1x9.5d T5 W2x4.6d T W2x4.6d W2.5X16q W2x4.6d T1.5 W2.5X16q S / Amber 24NA 12 21/7 3047LL W3X16d W2.5X16d W2.5x16d S8 W3X16d T Amber 7440NA / Amber 7440LL W2x4.6d 12 21/ /5 7443LL W2x4.6d T /5 Amber 7443NA

25 Instrument Panel s 25 B10d BG d 12 3 brown base miniature halogen black base black base miniature halogen B8.3d BG d 12 2 white base black base grey base B8.5d BG8-5.5d black base black base contacts on the bottom black base green base grey base BX8.4d B8.7d 12 2 mint green base black base grey base green base green base beige base orange base

26 26 Instrument Panel s BX8.5d W2X4.6d blue violet base white base beige base white base light blue base light green base brown base EBS N beige base EBS R yellow base EBS R brown base

27 Instrument Panel s 27

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