Durability Test Mode for LED Adaptive Front Lighting System by Failure Mode Effect Analysis

Recently, many kinds of new technology systems are adapted to a new developing vehicle. However the field usage information of a new technology system could not be easily obtained because it has not been used by customers. It is not easy to evaluate the reliability and durability of this system. In this research, the durability test mode of a new Adaptive Front Lighting System (AFLS) with Light Emitting Diodes (LEDs) as a new light source has been developed for a new large luxury sedan vehicle. First of all, the failure mode effect was analyzed by considering failure mechanism for each component. The thermal, vibrational, operational and electrical loads were investigated. The Road Load Data Acquisition (RLDA) technique was used to collect the vibration and temperature of an AFLS in a proving ground. The vibration test mode was designed by a Power Spectral Density (PSD) approach. The customer usage data was used for making the target cycles of operational movement such as swiveling. The customer usage data have been gathered by a newly developed data monitoring system using a smartphone, Controller Area Network (CAN) Bluetooth dongle. The thermal loads making an effect on life time of LEDs was investigated. The combined environmental durability test mode has been developed for a new AFLS. The test mode was verified by comparing between the accelerated rig test and a proving ground test.