Modular design of the LED vehicle projector headlamp system

[[abstract]]A well designed headlamp for a vehicle lighting system is very important as it provides drivers with safe and comfortable driving conditions at night or in dark places. With the advances of the semiconductor technology, the LED has become the fourth generation lighting source in the auto industry. In this study, we will propose a LED vehicle projector headlamp system. This headlamp system contains several LED headlamp modules, and every module of it includes four components: focused LEDs, asymmetric metal-based plates, freeform surfaces, and condenser lenses. By optimizing the number of LED headlamp modules, the proposed LED vehicle projector headlamp system has only five LED headlamp modules. It not only provides the low-beam cutoff without a shield, but also meets the requirements of the ECE R112 regulation. Finally, a prototype of the LED vehicle projector headlamp system was assembled and fabricated to create the correct light pattern