In­dia Ja­pan Light­ning fo­cuses on multi-re­flec­tor all-LED head­lamps

IJL wants to lead the In­dian mar­ket with cost-ef­fec­tive, safe and innovative tech­nolo­gies.

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The Chen­nai-based In­dia Ja­pan Light­ing (IJL), a 70:30 joint ven­ture be­tween Koito Ja­pan and Lu­cas TVS, is de­vel­op­ing multi-re­flec­tor all LED head­lamps. In or­der to pro­vide cost ef­fec­tive LED solution to the In­dian mar­ket it is work­ing on var­i­ous innovative solutions. Though the Light Emit­ting Diode (LED) head­lamps are costlier than the con­ven­tional halo­gen bulbs, they are be­com­ing pop­u­lar ow­ing to the var­i­ous ad­van­tages. The lamp man­u­fac­tur­ers are work­ing on var­i­ous new con­cepts to make LEDs more af­ford­able.

Since last year IJL has been sup­ply­ing LED head­lamps in the In­dian mar­ket for Toy­ota In­nova Crysta, Toy­ota For­tuner and Maruti Suzuki Ig­nis. The head­lamp sup­plied by IJL for For­tuner is bi-LED (Low beam, high beam, park­ing and DRL) and for Ig­nis the com­pany started sup­pling full biLED head­lamp. Last year for IJL, For­tuner and Ig­nis are the 2 new pro­grammes. For Ig­nis the com­pany also sup­plies halo­gen ver­sion for the low-end mod­els. The light man­u­fac­turer also started sup­ply­ing halo­gen head­lamps for Isuzu and it is in talk for sup­ply­ing LED head­lamps.

New tech­nol­ogy

In or­der to of­fer af­ford­able solution to the In­dian mar­ket, IJL has de­vel­oped a PES (Pro­jec­tor El­lip­soidal Sys­tem) mod­ule for head­lamps. The PES mod­ule that IJL has de­vel­oped is for halo­gen, high-in­ten­sity dis­charge (HID) and LED light sources. Talk­ing to Auto

Com­po­nents In­dia at the plant near Chen­nai, Senthil Vela­van R, Head, Prod­uct De­vel­op­ment, IJL, said, “Cur­rently we have wide range of PES mod­ules and now we are work­ing on multi re­flec­tor LED head­lamps. In pro­jec­tor head­lamps there are some lim­i­ta­tions which can­not be elim­i­nated be­yond a cer­tain limit, hence the cost op­ti­mi­sa­tion is lim­ited. There­fore now we are work­ing on multi-re­flec­tor LED head­lamps which will have multi-par­a­bola (multi-re­flec­tor) that con­sists of low and high­beam. We are work­ing on this new tech­nol­ogy for the In­dian mar­ket, which will en­able us to re­duce the cost and make LED lamps more af­ford­able. The other

tech­nol­o­gyogy that we are work­ing is sig­na­ture light­ing for sig­nalling. alling. For th­ese sig­na­turere light­ing we are work­ing on 4 tech­nolo­gies; Spot LED, mul­ti­plelti­ple re­flec­tor, light guide andnd dif­fu­sion lens.”

The multi-re­flec­tor head­lamps re­duce cost and al­low de­sign flex­i­bil­ity. Cur­rently the trend is sig­na­ture light­ing in­side the head­lamps. With the in­tro­duc­tion of multi-re­flec­tor head­lamps, the head­lamp it­self will be­come sig­na­ture. The size of the head­lamp comes down when mi­grat­ing from halo­gen to pro­jec­tor, now with the in­tro­duc­tion of mul­tire­flec­tor the size of the lamps goes down fur­ther and gives great flex­i­bil­ity in de­sign­ing the head­lamp in a sleeker man­ner. Since the head­lamp it­self be­comes a sig­na­ture lamp, it can fur­ther elim­i­nates the sig­na­ture lamps that are cur­rently used. In this new sys­tem the op­tics is matched to the profile of the lamp, there­fore when the lamp is ‘on’ there is no dummy sur­face, it glows com­pletely and pro­vides sig­na­ture for the ve­hi­cle. Cur­rently the pro­jec­tor head­lamp is of­fer­ing some styling (sig­na­ture) and with the help of multi-re­flec­tor head­lamps the sig­na­ture goes to the next level. Com­par­ing to the con­ven­tional LED head­lamps to multi-re­flec­tor head­lamps the cost sav­ing would be around 25%. Since the multi-re­flec­tor head­lamp comes with huge cost sav­ing ad­van­tage, IJL is plan­ning to in­tro­duce it even in low-cost cars.

‘Al­ways on head­lamps’ have be­come manda­tory from April 1, 2017 for two-wheel­ers, there­fore by us­ing LED, the life goes up.

Con­ven­tional bulbs re­quire fre­quent re­place­ment. LEDs have more life, save power and also of­fer scope of weight re­duc­tion. The life of LEDs goes up if they are op­er­ated in the op­ti­mum tem­per­a­ture by pro­vid­ing ad­e­quate heat sinks.

PES with­out fan

“Cur­rently our bi-LED PES mod­ules is hav­ing a fan to re­move the heat. Now we are com­ing out with a PES mod­ule with­out fan. Now we are

work­ing with LED man­u­fac­turer for low cur­rent LEDs, which dis­si­pates less heat ther­fore the fan is elim­i­nated. By us­ing this tech­nol­ogy the power con­sump­tion for low-beam alone is re­duced by 66% com­pared to halo­gen. When both high and low-beams are used to­gether we save around 39% of power. When the same sys­tem is used with­out fan, we save around 30% more power than the one with fan. There­fore the pro­jec­tor mod­ule with­out fan will be the only solution what we are plan­ning to of­fer in the In­dian mar­ket af­ter we com­plete this de­vel­op­ment,” Vela­van said.

For cost com­pet­i­tive­ness, IJL is work­ing on 4 ar­eas; weight re­duc­tion, parts count re­duc­tion, lo­cal­i­sa­tion and man­u­fac­tur­ing im­prove­ments. Un­der weight re­duc­tion pro­gramme, the com­pany is work­ing on re­duc­ing 10-20% of weight. With­out af­fect­ing the per­for­mance of the lamps ,IJL is work­ing on var­i­ous con­cepts to re­duce weight by thick­ness op­ti­mi­sa­tion with new ma­te­rial and gate op­ti­mi­sa­tion.

By lo­cal­is­ing some of the parts like auto lev­eller, pro­jec­tor units, con­trollers for LEDs, light guides and tool­ings IJL has sub­stan­tially re­duced the cost. In man­u­fac­tur­ing, ear­lier the com­pany used to as­sem­ble sin­gle prod­uct in 1 line, now the mul­ti­ple prod­uct is man­u­fac­tured in sin­gle as­sem­bly line with quick changeover. Ef­fi­ciency im­prove­ment is un­der progress with the in­tro­duc­tion of Kan­ban sys­tem. IJL has also re­duced the length of the as­sem­bly line by op­ti­mis­ing the ma­chine size to re­duce the op­er­a­tor move­ment and save time. In man­u­fac­tur­ing the com­pany grouped 4 func­tions; Plan­ning, Pur­chase, Stores and Ware­house and formed a de­part­ment PCLD to con­trol from plan­ning stage to cus­tomer de­liv­ery stage. Th­ese ini­tia­tives made IJL to save around 10-15% on over­all lamp cost.

Re­cently the Indo-Ja­panese JV com­pany en­hanced its ca­pa­bil­i­ties by hav­ing full de­sign and de­vel­op­ment in­clud­ing styling and de­sign of LED head­lamps. Vela­van said, “We fo­cussed on the de­sign and de­vel­op­ment mainly for the ad­vanced tech­nol­ogy lamps like LED head­lamps, sim­u­la­tion, in-house de­sign of elec­tronic con­trollers, mould de­vel­op­ment and test­ing ca­pa­bil­ity en­hance­ments. This made us to re­duce the over­all de­vel­op­ment cost. If we do any de­vel­op­ment in In­dia the de­vel­op­ment cost will be only one third com­par­ing to Ja­pan or other coun­tries. Fur­ther, IJL con­tin­ues to ac­quire cut­ting edge ad­vanced tech­nol­ogy from Koito to lead In­dian mar­ket. This knowl­edge ac­qui­si­tion is gained by work­ing for ad­vanced tech­nol­ogy lamps by IJL en­gi­neers at Koito in Ja­pan.”

PES pro­duc­tion

In or­der to im­prove the qual­ity of the LED head­lamps, IJL started man­u­fac­tur­ing with PU glue for join­ing the lens and body. Ear­lier the com­pany was us­ing hot melt and now by us­ing PU glue there are many chal­lenges but keep­ing the qual­ity in mind IJL have over­come it and es­tab­lished a PU glue man­u­fac­tur­ing unit at the IJL plant. Also it has es­tab­lished anti-haze man­u­fac­tur­ing, which helps in avoid­ing sweat that is cre­ated in­side the lamp due to tem­per­a­ture change. Re­cently it has also added the de­sign and man­u­fac­tur­ing ca­pa­bil­i­ties of LED PES mod­ule and auto lev­el­ling.

Con­struc­tion of multi-re­flec­tor all LED head­lamp

Multi-re­flec­tor all LED head­lamp

Toy­ota For­tuner head­lamp is man­u­fac­tured by IJL

PES Mod­ule with fan

IJL also man­u­fac­tures Se­quen­tial sig­nal lights

Toy­ota In­nova Crysta head­lamp un­der­goes test­ing at end of the as­sem­bly line

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