J-RO'S ADAPTIVE XENON LIGHTS: THE PROJECT

[J-Ro]

Okay, so I've made a bit of headway... not as much as I would have liked, but enough that I think this is definitely the way to go.

Here are the plastic balls I ordered. Two 4" and two 5".


I cut them in half and cut circular holes in two halves for the projector lens, and another hole in one of the 4" pieces for the back.


Here is the 4" on the front:


And the 5" on the front:


When trying to fit the above two pieces into the stock reflector housing, the 4" seems to small and the 5" too big. I think I may end up using some mold-release compound and some super heavy-duty epoxy at work to build up the area around the stock reflector to make the 4" fit nicely. That will also give it a better seat.

Here is the back piece. When it is ready to fit, I will glue it to the back of the projector and seal it.


The idea is that the projector will basically be sandwiched between the stock reflector and the back half of the housing. Below is how it would sit against the back of the housing. I want to make an insert in the hole to hold a large-diameter o-ring in order to create a seal while still allowing the projector to move.


There are still some hold-ups with this idea, but I think this is a better way to go.
If anyone sees anything catastrophic that I'm walking into, please let me know, or if you have any good ideas too... I promise I'll credit you when I write the DIY

Jason

[Sion0x]

I'm no guru on lighting, but so far it looks like you've done a fantastic job!

I couldn't even dream of doing that!

I wanna see the finished product as well

[J-Ro]

Oh, that's another thing... I'm thinking of painting the inside of the projector area ABM to match the rest of my car. Might look nice with a polished aluminum shroud :)

[marc-o-lishuz]

I wonder how heat-resistant those plastic enclosures are.

[J-Ro]

That's a good point marc, but I don't think it's enough to melt polypropylene. If it doesn't melt the headlight housing, it probably won't melt those.
However, an oven test might be in order just in case :)

[marc-o-lishuz]

Well in normal operation, HIDs do give off less heat than halogens.

Yeah, oven test sounds good (just the plastic enclosures though... I don't think you wanna bake the projectors

[hoanger]

whoa jason, thats pretty intuitive
i'm having questions about a simple retrofit
and here you are doing an adaptive lighting system
...
keep up the good work!

[ethlar]

could also test them by putting bulbs in and firing them up. Shut it down if it does start to melt

[striker_1818]

Those look like RL shrouds

[J-Ro]

Okay, for all interested, the programming is now complete. All that remains for the electrical part is to mount all the circuitry onto a permanent board and put it in a case.
Here is the program, if anyone wants to replicate this and give it a try.
Anything after a single apostrophe is a comment. Also, I kept both debugging lines, but commented them out to keep them from bogging down the processor.
*EDIT* Sorry, but tabs don't seem to work here... the program is MUCH easier to read with the tabs in place.

'ProjectorControl.bs2
'Author: J-Ro
'Lines: 134
'Written: Dec. 14/2006
'Updated: Feb. 03/2007
'Content: This program provides control of the servomotors actuating xenon projector headlights.
' Real-world analog inputs are variable voltage via a potentiometer connected to the steering
' column and variable voltage via the speedometer signal. These analog signals are fed through
' an RC timer circuit into the BASIC Stamp I/O pins and indirectly converted from analog to
' digital via thePBASIC RCTIME command. The servomotors are powered by a dedicated 5V regulator,
' and the signal voltage is fed directly from the stamp I/O pins.
'
'Features: - Real-time control of projector position
' - Re-centering when car is stopped/re-positioning when car moves
' - Speed-sensitive control, preventing unnecessary movement during high-speed, low-wheel-movement
' maneuvers, such as lane changes
' - easily expandable to include driver-defined (rather than program-defined) settings, such as
' maximum angle, speed sensitivity and inclusion/exclusion of centering feature
'
'Hardware: - 1× Basic STAMP 2 OEM kit
' - 2× TowerPro SG5010 remote-control-style servomotors
' - 1× ML7805A voltage regulator (TO-220 package)
' - 1× 10 kohm, 10-turn potentiometer (McMaster-Carr p/n 7436K31)
' - 1× green, 2× red LEDs
' - 2× 10, 2× 470, 3× 510 ohm 1/4W resistors
' - 2× 1 µF, 50V polar electrolytic capacitors
' - 1× 1A quick-blow AGU fuse, fuse holder
' - 22AWG wire, red/black
' - circuit board etching kit
' - case

'-------------------------------------------------------------------------------------------------------------

' {$STAMP BS2}
' {$PBASIC 2.5}

'Variables:
SPEED_IN VAR Word 'Speed signal from speedometer (units) (RCTIME unit = 2 µs)
WHEEL_IN VAR Word 'Wheel signal from potentiometer (units)
WHEEL_REV VAR Word 'Reverse of wheel signal (units)
FACTOR VAR Word 'Wheel vs. speed threshold

'Calibration constants:
SPEED_ZERO CON 271 'Zero value for speed (units)
MAX_L CON 550 'RCTIME value for max left position (units)
CENTRE CON 420 'RCTIME value for centre position (units)
MAX_R CON 240 'RCTIME value for max right position (units)
THR_SPD CON 5000 'Speed threshold (units)
THR_CTR CON 5 'Half of centre threshold (units)
MULT CON 2 'Multiplier for relative movement of outside light

'-------------------------------------------------------------------------------------------------------------

MAIN: 'Main program

DIRS=%1111000000000000 'Set stamp I/O pins 0-3 as outputs and 4-15 as inputs

'Pin IDs:
'0 - Left servo OUT
'1 - Right servo OUT
'2 - Left LED OUT
'3 - Right LED OUT
'13 - Direction IN
'14 - Wheel position IN (RC timer circuit)
'15 - Speedometer IN

'PROGRAM LOAD 'Blink L/R LEDs once to confirm program is loaded
LOW 2 'LEDs off
LOW 3
PAUSE 500
HIGH 2 'LEDs on
HIGH 3
PAUSE 500
LOW 2 'LEDs off
LOW 3
PAUSE 500

DO
IF(IN13=1) THEN GOSUB REV_SERVO 'If reverse gear has been selected
GOSUB GET_SPEED 'Go to GET_SPEED subroutine to store speed data
GOSUB GET_POS 'Go to GET_POS subroutine to store wheel position data
FACTOR=SPEED_IN*ABS(CENTRE-WHEEL_IN)
IF(SPEED_IN>SPEED_ZERO) THEN 'Car must be in motion
'------------------
' DEBUG DEC WHEEL_IN, " ", DEC MAX_R, " ", DEC MAX_L, " ", DEC SPEED_IN, " ", DEC IN13, " ", DEC FACTOR, CR
'------------------
IF(SPEED_IN*ABS(CENTRE-WHEEL_IN)<THR_SPD) THEN 'If wheel vs. speed threshold is not being exceeded
LOW 2
LOW 3
PULSOUT 0, CENTRE
PULSOUT 1, CENTRE
ELSEIF(WHEEL_IN>MAX_R AND WHEEL_IN<MAX_L) THEN 'Keep signals between max L/R positions (~80° sweep)
IF(WHEEL_IN>(CENTRE+THR_CTR)) THEN 'Left turn, 2*THR_CTR threshold (keeps from jumping L/R)
HIGH 2 'Left LED on
LOW 3
PULSOUT 0,WHEEL_IN
PULSOUT 1,((WHEEL_IN-CENTRE)/MULT)+CENTRE 'Want less movement on outside light
ELSEIF(WHEEL_IN<(CENTRE-THR_CTR)) THEN 'Right turn, 2*THR_CTR threshold (keeps from jumping L/R)
LOW 2 'Right LED on
HIGH 3
PULSOUT 0,CENTRE-((CENTRE-WHEEL_IN)/MULT) 'Want less movement on outside light
PULSOUT 1,WHEEL_IN
ENDIF
ELSEIF(WHEEL_IN>MAX_L) THEN 'If wheel input signal goes beyond max left position
HIGH 2
LOW 3
PULSOUT 0,MAX_L
PULSOUT 1,((MAX_L-CENTRE)/MULT)+CENTRE
ELSEIF(WHEEL_IN<MAX_R) THEN 'If wheel input signal goes beyond max right position
LOW 2
HIGH 3
PULSOUT 0,MAX_R
PULSOUT 1,CENTRE-((CENTRE-MAX_R)/MULT)
ELSE 'Centre lights under all other conditions
HIGH 2
HIGH 3
PULSOUT 0, CENTRE
PULSOUT 1, CENTRE
ENDIF
ELSEIF(SPEED_IN<=SPEED_ZERO) THEN 'Centre the lights if the car is stopped
LOW 2
LOW 3
PULSOUT 0, CENTRE
PULSOUT 1, CENTRE
ELSE 'Error case (covers any/all erroneous I/O)
PULSOUT 0, CENTRE
PULSOUT 1, CENTRE
DO 'Flash L/R LEDs to indicate error
LOW 2
LOW 3
PAUSE 250
HIGH 2
HIGH 3
PAUSE 250
LOOP
ENDIF
LOOP 'Run continuously
END

'-------------------------------------------------------------------------------------------------------------

GET_POS: 'Subroutine to acquire wheel position data
HIGH 14 'Charge the capacitor
PAUSE 2
RCTIME 14,1,WHEEL_IN 'Store wheel position data to WHEEL_IN
RETURN

GET_SPEED: 'Subroutine to acquire speed data
HIGH 15 'Charge the capacitor
PAUSE 2
RCTIME 15,1,SPEED_IN 'Store speed data to SPEED_IN
RETURN

REV_SERVO: 'Subroutine that reverses servo output
DO WHILE(IN13=1)
GOSUB GET_SPEED 'Go to GET_SPEED subroutine to store speed data
GOSUB GET_POS 'Go to GET_POS subroutine to store wheel position data
WHEEL_REV=2*CENTRE-WHEEL_IN 'Function inverts WHEEL_IN about CENTRE for WHEEL_REV
'-------
' DEBUG DEC WHEEL_REV, " ", DEC MAX_R, " ", DEC MAX_L, " ", DEC SPEED_IN, " ", DEC IN13, CR
'-------
IF(WHEEL_REV>MAX_R AND WHEEL_REV<MAX_L) THEN 'Keep signals between max L/R positions (~80° sweep)
IF(WHEEL_REV>(CENTRE+THR_CTR)) THEN 'Wheel left, lights right
HIGH 2 'Left LED on
LOW 3
PULSOUT 0,WHEEL_REV
PULSOUT 1,((WHEEL_REV-CENTRE)/MULT)+CENTRE 'Want less movement on outside light
ELSEIF(WHEEL_REV<(CENTRE-THR_CTR)) THEN 'Wheel right, lights left
LOW 2 'Right LED on
HIGH 3
PULSOUT 0,CENTRE-((CENTRE-WHEEL_REV)/MULT) 'Want less movement on outside light
PULSOUT 1,WHEEL_REV
ENDIF
ELSEIF(WHEEL_REV>MAX_L) THEN 'If wheel input signal goes beyond max left position
HIGH 2
LOW 3
PULSOUT 0,MAX_L
PULSOUT 1,((MAX_L-CENTRE)/MULT)+CENTRE
ELSEIF(WHEEL_REV<MAX_R) THEN 'If wheel input signal goes beyond max right position
LOW 2
HIGH 3
PULSOUT 0,MAX_R
PULSOUT 1,CENTRE-((CENTRE-MAX_R)/MULT)
ELSE 'Centre lights under all other conditions
HIGH 2
HIGH 3
PULSOUT 0, CENTRE
PULSOUT 1, CENTRE
ENDIF
LOOP
IF NOT(IN13=1) THEN 'Centre lights, then wait 5 s
HIGH 2 'Re-centers headlights while driver is shifting out of
HIGH 3 'reverse and gives time to start driving forwards
PULSOUT 0, CENTRE 'before main routine begins again
PULSOUT 1, CENTRE
PAUSE 5000
ENDIF
RETURN

[Nomar06]

Evil genious still up to no good.....I like!!!!

I actually saw a Ebay auction for the lexus turning projectors and motors. I was a bit shocked that it didnt go over $200 but I guess you would still have to do all the programming for it.

[J-Ro]

Originally Posted by Nomar06

Evil genious still up to no good.....I like!!!!

I actually saw a Ebay auction for the lexus turning projectors and motors. I was a bit shocked that it didnt go over $200 but I guess you would still have to do all the programming for it.

I guess I probably should have thought of that
God bless ebay though... I may have to keep an eye out for more auctions like that.
Yeah, you would still have to do the programming and interface it with the car, but at least the mechanical crap would be taken care of.
Thanks for the find, Nomar. :)

[Nomar06]

Just searched again for shits and giggles

http://cgi.ebay.com/ebaymotors/2007-...spagenameZWDVW

Looks like it turns inside of the mounting bracket and inside another shroud with a lense.


Not sure if this is adaptive either?
http://cgi.ebay.com/ebaymotors/2007-...spagenameZWDVW

[Nomar06]

search a little deeper and found the set for decent price, lol

http://cgi.ebay.com/ebaymotors/LEXUS...spagenameZWDVW

[truflip]

Originally Posted by J-Ro

Go big or go home, that's what I always say. And I never pass up a challenge (as if that weren't already painfully obvious) :)

I challenge you to retrofit my headlights this spring/summer. i will provide housing, food and beer!

[J-Ro]

Thanks for the finds, Nomar. I think the problem with those is that they look way too bulky to actually make them work in a retrofit.
Car designers have the luxury of taking that adaptive projector assembly and building around it... unfortunately we don't
I'm going to go in to work today (that's where all the tools are :)) and see if I can make some more headway.

[J-Ro]

Originally Posted by truflip

I challenge you to retrofit my headlights this spring/summer. i will provide housing, food and beer!

Well, I'm only an hour away, so for food and beer, how could I say no?

[truflip]

omg! really? thats so cool man!
but since you're only an hour away.. i can come there n bring beer lol
i was jus checkin out ur other pics with the eibachs. the rides so sick!

[J-Ro]

Hopefully these pictures will give you a better idea of what my plan is with these plastic ball things...

Here are the two halves of the ball. I have been progressively shaving off plastic because the two halves have to meet in order to turn the projector into kind of a ball pivot. It took me a while to realize that they have to go back into a sphere, but I finally got it though my thick head :)
I took out the glass lens because I didn't want to damage it from handling the projector so much.


The picture below shows how the projector will be sandwiched between the reflector and the back half of the housing. Obviously there are still some fitment issues that I have to work out.


Here's what it looks like from the front. The joint area between the projector and the stock reflector will be filled with epoxy to build up the area to provide a seat for the projector and to make it look half-decent. Try to imagine it with a nice, polished aluminum shroud and painted black or ABM to match my car... I can't decide :)