The dual climate chamber is a device that we use at DEVINN to test headlights (especially prototype headlights) to ensure that the headlight of a vehicle in the final development phase will not fog up during operation and therefore its functionality and lifetime will not be compromised in any way.
One of the key topics we deal with at DEVINN is lights for cars. In addition to developing special lights for racing cars, we also test lights for production cars. For this purpose, we have equipped our laboratory with a dual climate chamber. What is the purpose of such a device, on what principle does it work and what are the advantages compared to testing lights during operation?
LED headlights and the fight against fogging
With theadvent of LED headlights, their luminosity has increased significantly, but the lower heat radiated into the interior of the reflector causes fogging problems. While this phenomenon does not have a major effect on functionality, it is criticised from a design point of view and therefore needs to be eliminated. The headlamp of a modern car is already a rather complex component, not only with regard to the electronics but also to ensure its correct functionality. During the development of the headlamp, operation in all climatic conditions must be taken into account and the best way to simulate such conditions and to correct any deficiencies in the design (e.g. by means of ventilation holes, choice of other materials, etc.) is by testing the headlamp in laboratory conditions.
Testing in the dual climate chamber perfectly simulates the car's exterior and interior environment
The dual climate chamber is a device that we use at DEVINN to test headlights (especially prototype headlights) to ensure that the headlight of a vehicle in the final development phase will not fog up during operation and therefore its functionality and lifetime will not be compromised in any way. The dual climate chamber allows us to simulate the climatic conditions in different planes. For example, by adjusting outdoor/indoor temperature, rain intensity, driving the car at a certain speed under certain weather conditions. These are all key factors that have a major influence on the correct functioning of the headlamp. The aim of the dual climate chamber testing is to provide the necessary output data for the designers to achieve, through gradual refinement, a state where the light will function without any limitations and thus provide the user with the expected functionality.
Our dual chamber consists of 3 parts that are connected together to best demonstrate the conditions that most often cause fogging of headlights:
1. The first climate chamber: imagine it as an outdoor environment that the light comes into contact with during operation. Here we can simulate the outdoor temperature effects that may affect the headlamp during operation (very high or very low temperatures). In extreme cases it is possible to control the temperature in the range from -70°C to 180°C)
2. The second climate chamber.
3. Middle part: this is the area where we can simulate rain at a temperature (from 0°C to 40°C) and thus significantly accelerate the cooling or heating of the headlight cover glass. Together with a fan placed inside, we are able to set the weather conditions at the desired temperature/humidity to simulate the driving of the vehicle.
Based on the tests, modifications are made to the headlight design
The test itself takes tens of hours in the climate chamber. Based on the detected data, which we pass on to the customer, design adjustments and subsequent verification tests are then carried out to verify the correct behaviour. In this way, the headlamp gradually becomes "perfect".
Tests in the climate chamber will not be affected by fickle weather
Field testing, i.e. driving tests, of course also have their place in the development phase. They are still used and will continue to be used. However, particularly in the context of headlight testing, we are faced with the fickleness and instability of the weather.
And here we come to what makes the dual climate chamber unique. It allows us to simulate conditions that are always identical and stable. It allows us to compare previous development versions of the headlamp after applying design changes. We are able to compare different headlamps under exactly the same climatic conditions faster and of course also significantly cheaper compared to driving tests in real conditions. For even more accurate test results with regard to airflow, the headlight chamber is also equipped with surrounding body parts to ensure that the tests are carried out with the highest possible validity and accuracy to match the real car in the production phase.
DEVINN is unique thanks to the operation of the dual climate chamber
We have been using the functional chamber in DEVINN for about a year and due to the existence of only 3 copies in the Czech Republic, its utilization is very intensive. DEVINN is the only purely development company in the Czech Republic that has such equipment, the other two chambers are owned by large headlight manufacturers and are therefore used exclusively for their own products. The headlights are tested in prototype and pre-series phases. Our chamber has thus been used for headlights that you can see, for example, on the Škoda KAMIQ and the facelifted Škoda Superb.
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