India Japan Lightning focuses on multi-reflector all-LED headlamps
IJL wants to lead the Indian market with cost-effective, safe and innovative technologies.
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.
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.”
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