Modular design of a high-efficiency LED headlamp system based on freeform reflectors

• We propose a modular method for the design of a high-efficiency LED headlamp system.
• The optical design and glare suppression are considered.
• An effective method is introduced to optimize the freeform reflector.
• The module has a high optical efficiency.
• The module can fully meet the ECE R112 regulation.

A modular of the LED headlamp system based on freeform reflectors is proposed. Glare suppression and optical design are taken into account during the module design. The proposed module consists of six LEDs and each of them has a freeform reflector correspondingly, which is constructed based on the light energy maps and Snell’s Law. Through lighting up different LEDs, the high-beam light and the low-beam light can be switched conveniently. With the proposed method, a module is designed and LUW HWQP LED source whose chip size is 1.0 mm×1.0 mm is adopted for the simulation. Results demonstrate that the lighting distribution can well fulfill the requirements of ECE R112 regulation without any other lenses, shields or baffles. Furthermore, the total optical efficiency can reach up to 80.29% and 81.16% for the low-beam light and high-beam light respectively.