This technical publication describes the automotive segmented reflector design process from first-order design to standards testing using ReflectorCAD® and the Advanced Systems Analysis Program (ASAP®) from Breault Research Organization (BRO). A brief discussion on some of the important issues in a general design philosophy is included, but the emphasis is on the detailed, modular design steps for segmented reflectors using ReflectorCAD, ASAP, and the ASAP add-in, ELTM (Exterior Lighting Test Module).
This methodology serves as a design road map for segmented headlamp design, but many of its components can also be used for performing general parametric analyses, sensitivity analyses, and tolerance analyses. (Note: Tolerancing can also be done from the ASAP user interface (UI). Both tolerancing and sensitivity analysis from the ASAP UI are under development.) The procedure can also be adapted for other headlamp designs, such as projector headlamp systems, and other types of automotive exterior lighting systems.
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bropn1150_reflector.pdf