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1 / 18 www.norpero.com
Thermal Simulation Report of Norpero 7 inch LED Headlight
Eyer Series
Design: Jack Deng Date: 20140915
2 / 18 www.norpero.com
1. Thermal radiation judgment standard of the LED chips:
1.1 The maximum junction temperature of LED chips:
1.1.1 High and Low beam LED chips Model: OSRAM KW H2L531.
The maximum junction temperature : Tj=150℃.
1.1.2 Angel eyes LED chips: HL‐A‐3014H378W‐S1‐08‐HR1.
The maximum junction temperature: Tj=110℃.
1.2 Judgement standard:
Test in the 28℃ condition while the thermal stability:
Requirement: High and Low beam LED chips junction temperature < Tstandard=145℃=Tj150℃-5℃.
Requirement: Angel eyes LED chips junction temperature < Tstandard=105℃=Tj110℃-5℃.
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2. Thermal simulation model and simulate conditions (High
beam and Angel eyes). 2.1 simulate conditions:
Project parameters
Product model 7’’ high low beam
led headlight
High beam LED chips
model
KW H2L531
High beam LED chips 2 PCS
High beam LED chips
junction temperature 150℃
High beam thermal
resistance
1.2K/W
High beam power 13.6W
Thermal power 10.88W
Angel eyes LED chips
model HL‐A‐
3014H378W‐S1
‐08‐HR1
Angel eyes LED chips 80 PCS
Angel eyes LED chips
junction temperature 110℃
Angel eyes thermal
resistance
125K/W
Angel eyes power 3.6W
Thermal power 2.88W
The direction of gravity
Model
Inner Structure
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Test temperature 28℃
2.2 Thermal simulation (High beam and Angel eyes). 2.2.1 Simulation process:
2.2.2 Conclusion:
The circuit board temperature of high beam:59.16℃;The circuit board temperature of angel eyes:72.57℃.
High beam LED junction temperature=59.16+13.6/2*1.2=67.32℃<Tstandard=145℃.So the thermal radiation is
fine.
Angel eyes LED junction temperature=72.57+3.6/80*125=78.195℃<Tstandard=105℃. So the thermal radiation is
Air flow inner The temperature distribution of the lights
Temperature ℃
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fine.
3. Thermal simulation (Low beam and Angel eyes). 3.1 Simulations condition:
Project parameters
Product model 7’’ high low beam led
headlight
Low beam LED
chips model
KW H2L531
Low beam LED
chips
2 PCS
Low beam LED
chips junction
temperature
150℃
Low beam thermal
resistance
1.2K/W
Low beam power 13.6W
Thermal power 10.88W
Angel eyes LED
chips model HL‐A‐3014H378W
‐S1‐08‐HR1
Angel eyes LED
chips
80 PCS
Angel eyes LED
chips junction
temperature
110℃
Angel eyes thermal
resistance
125K/W
Angel eyes power 3.6W
Thermal power 2.88W
Inner Structure
Direction of gravity
Model
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Test temperature 28℃
3.2 Thermal simulation (Low beam and Angel eyes). 3.2.1 Simulation process:
3.2.2 Conclusion:
The circuit board temperature of high beam:61.51℃;The circuit board temperature of angel eyes:71.67℃.
Low beam LED junction temperature=61.51+13.6/2*1.2=69.67℃<Tstandard=145℃. So the thermal radiation is
fine.
Angel eyes LED junction temperature=71.67+3.6/80*125=77.295℃<Tstandard=105℃. So the thermal radiation is
Air flow inner The temperature distribution of the lights
Temperature ℃
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fine.
4. Thermal simulation (High, Low beam and Angel eyes). 4.1 Simulation condition: Project parameters
Product model 7’’ high low beam led
headlight
High and Low beam
LED chips model
KW H2L531
High and Low beam
LED chips
2 PCS
High and Low beam
LED chips junction
temperature
150℃
High and Low beam
thermal resistance
1.2K/W
High beam power 13.6W
Low beam power 13.6W
High beam Thermal power
10.88W
Low beam Thermal power
10.88W
Angel eyes LED chips
model HL‐A‐3014H378W‐S1‐08‐HR1
Angel eyes LED chips 80 PCS
Angel eyes LED chips
junction temperature 110℃
Angel eyes thermal
resistance
125K/W
Angel eyes power 3.6W
Thermal power 2.88W
Direction of gravity
Model
Inner structure
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Initial temperature 28℃
4.2 Thermal simulation (High, Low beam and Angel eyes). 4.2.1 Simulation process:
4.2.2 Conclusion:
The circuit board temperature of high beam:73.91℃;The circuit board temperature of low beam:75.79℃;The light
board temperature of angel eyes:85.57℃.
High beam LED junction temperature=73.91+13.6/2*1.2=80.71℃<Tstandard=145℃. So the thermal radiation is
fine.
Low beam LED junction temperature=75.79+13.6/2*1.2=82.59℃<Tstandard=145℃. So the thermal radiation is
fine
Angel eyes LED junction temperature=71.67+3.6/80*125=91.2℃<Tstandard=105℃. So the thermal radiation is
flow trajectories The temperature contoured of the lights
Temperature ℃
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fine.
5. Experimental Verification. 5.1 Goal:
1) Verify the thermal radiation.
2) Compare the simulation result to the realistic.
3) Sample for test:
Model: 7 inch high low beam led headlight.
High beam LED chips: OSRAM KW H2L531, 2PCS; Low beam LED chips: OSRAM KW H2L531, 2PCS
Angel eyes LED chips: HL A 3014H378W S1 08 HR1, 80PCS
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5.2 Experimental test (High beam and Angel eyes). 5.2.1 Working conditions test:
Front side
Input Volt and current
Condition temperature and Humidity
Working conditions test
(High beam and Angel eyes)
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5.2.2 Experimental test (High beam and Angel eyes). Tested Results:
Project Results
Sample High beam
+Angel eyes
Input current 1.72A
Input volt 12V
Input power 20.64W
High beam
power
13.39W
Angel eyes
power
3.65W
The initial
temperature of
the condition
28℃
High beam
thermal
resistance
1.2K/W
Angel eyes
thermal
resistance
125K/W
High beam LED
chips junction
temperature
67.73℃
Angel eyes LED
chips junction
temperature
74.51℃
Test points and results
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5.3 Experimental test (Low beam and Angel eyes). 5.3.1 Working conditions test:
Working conditions test
(Low beam and angel eyes) Condition temperature and Humidity
Input Volt and current
Front side
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5.3.2 Experimental test (Low beam and Angel eyes). Tested Results
Project Result
Sample Low beam +Angel
eyes
Input current 1.72A
Input volt 12V
Input power 20.47W
Low beam
power
13.48W
Angel eyes
power
3.65W
The initial
temperature of
the condition
28℃
Low beam
thermal
resistance
1.2K/W
Angel eyes
thermal
resistance
125K/W
Low beam LED
chips junction
temperature
72.19℃
Angel eyes LED
chips junction
temperature
72.81℃
Test points and results
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5.4 Experimental test (High, Low beam and Angel eyes). 5.4.1 Working conditions test:
Front side
Working conditions test
(High beam, Low beam and angel eyes)
Condition temperature and Humidity
Input current
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5.4.2 Experimental test (High, Low beam and Angel eyes).
Tested Results: Project Result
Sample High+low beam
+Angel eyes
Input current 3.06A
Input volt 12V
Input power 36.72W
Hihg beam 13.39W
Low beam power 13.48W
Angel eyes power 3.65W
The initial
temperature of the
condition
28℃
High beam
thermal resistance
1.2K/W
Low beam
thermal resistance
1.2K/W
Angel eyes
thermal resistance
125K/W
Low beam LED
chips junction
temperature
84.23℃
Low beam LED
chips junction
temperature
87.79℃
Angel eyes LED
chips junction
temperature
89.30℃
Test points and results
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6. Data collection In 28℃ tested condition: NO. Function Experimental
Input current
(A)
Input volt
(V)
LED
power(W)
Thermal
resistance
(K/W)
Temperature of
Circuit board
(℃)
LED chips junction
temperature
(℃)
Working condition 1. High beam 1.72 12.0 13.39 1.20 59.7 67.73
Angel eyes 3.65 125 68.8 74.51
Working condition 2. Low beam 1.72 11.9 13.48 1.20 64.1 72.19
Angel eyes 3.65 125 67.1 72.81
Working condition 3. High beam 3.06 12.0 13.39 1.20 76.2 84.23
Low beam 13.48 1.20 79.7 97.79
Angel eyes 3.65 1.25 83.6 89.30
NO. Function Simulation
Input current
(A)
Input volt
(V)
LED
power(W)
Thermal power
(K/W)
Temperature of
Circuit board
(℃)
LED chips junction
temperature
(℃)
Working condition 1. High beam 1.72 12.0 13.60 10.88 59.16 67.32
Angel eyes 3.60 2.88 72.57 78.195
Working condition 2. Low beam 1.72 11.9 13.60 10.88 61.51 69.67
Angel eyes 3.60 2.88 71.67 77.295
Working condition 3. High beam 3.06 12.0 13.60 10.88 73.91 80.71
Low beam 13.60 10.88 75.79 82.59
Angel eyes 3.60 2.88 85.57 91.20
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The test result in 55℃ working condition calculated base on the above tested result: NO. Function Experimental
Input current
(A)
Input volt
(V)
LED
power(W)
Thermal
resistance
(K/W)
Temperature of
Circuit board
(℃)
LED chips junction
temperature
(℃)
Working condition 1. High beam 1.72 12.0 13.39 1.20 86.70 94.73
Angel eyes 3.65 125 95.80 101.51
Working condition 2. Low beam 1.72 11.9 13.48 1.20 91.10 99.19
Angel eyes 3.65 125 94.10 99.81
Working condition 3. High beam 3.06 12.0 13.39 1.20 103.20 111.23
Low beam 13.48 1.20 106.70 124.79
Angel eyes 3.65 1.25 110.60 116.30
Conclusion: 1. The experimental tested results of these three working condition were close to the simulative results in the 28℃ working condition.
2. The tested result of angel eyes were lower than the simulative results as the decorative component were chrome-plated to help
radiating.
3. The all LED chips Junction temperature TJ<Tstandard in 28℃ working condition.
4. The LED chips Junction temperature calculated in the Working condition 3:
High beam LED chips Junction temperature: 84.23+(55-28)=111.23℃<Tstandard=145℃, thermal radiation is ok.
Low beam LED chips Junction temperature: 97.79+(55-28)=124.79℃<Tstandard=145℃, thermal radiation is ok.
Angel eyes LED chips Junction temperature: 89.30+(55-28)=116.30℃> Tstandard=105℃, thermal radiation is insufficient.
5. Suggest: when the High low beam were on the angel eyes should be off.
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Thank you!