Feasibility Study: Development of a Headlight Module for Agricultural Technology

29.03.2021

Fried was engaged to carry out a feasibility study as part of a joint project with an internationally leading agricultural technology manufacturer. The study examines how a modular system can be created through the intelligent grouping of individual headlights in order to leverage design and savings potential.

Purpose of the Study

The task is complex and includes some special challenges. In order to develop a headlamp, several requirements and conditions have to be taken into account. The following factors were investigated:

Available installation space
Variants investigation
Required light output
Thermal management

Procedure

The first step was to draw up a specification sheet containing all the requirements and general conditions. Among other things, ambient temperatures, standards and guidelines, material selection, electrical and illumination requirements and available installation space were defined. The requirements specification creates a clear basis and can also be used when it comes to sourcing.

Installation Space

Design models were used to determine the volume of the installation space. The available volume was constructed as a component part for housing. In order to achieve as much light output as possible with low heat input at the same time, attempts were made to make the installation space as large as possible. As build variants are created via, it was possible to use identical hardware parts throughout.

Luminance

The required amount of light is very high with tens of thousands of lumens per spotlight. This enables bright illumination of the agricultural area. To achieve this light output it is important to know, that each additional pane of glass reduces the amount of light and leads to further heat input. The risk of soiling from the inside must also be taken into account, as this may lead to a reduction of light output. Consequently, an intelligent ventilation system is necessary.

Thermal Management

The high-performance LEDs require a high heat dissipation, because high temperatures would shorten the life of the LED. When developing a closed headlamp, it is therefore necessary to check the heat and humidity distribution previously with help of a simulation. Based on simulation results, the introduction of a heat sink can be considered. In addition, active cooling with a connection to the outside airflow can ensure optimal temperature and moisture distribution within the headlight module.

Conclusion

In the feasibility study Fried developed a headlight concept. The commercial and technical requirements were checked and different design options developed. The complex task could be successfully completed through the holistic approach of development, design, selection of manufacturing processes and partners.

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