Creating DRL as European regulations R87 required

[RusDyr]

Good day.
I wish to create LED DRL that totally meet the requirements of European regulations UNECE №87 ("Daytime running lamps for power-driven vehicles").

This regulations contains four important requirement:
1. Light distribution
2. Intensity of light
3. Illumination surface
4. Colour of light.


Light distribution:

Intensity of light:

7.1. The luminous intensity of the light emitted by each lamp shall not be less
than 400 cd in the axis of reference.

7.2. Outside the reference axis and within the angular fields defined in the arrangement
diagram in Annex 7 to this Regulation, the intensity of the light emitted by each
lamp must:

7.2.1. In each direction corresponding to the points in the table of standard light
distribution reproduced in Annex 3 to this Regulation, be not less than the minimum
specified in paragraph 7.1. above, multiplied by the percentage specified in the said
table of the direction in question, and

7.2.2. not exceed 1,200 cd in any direction the lamp is visible.

7.3. Moreover, throughout the field defined in the diagram in Annex 7, the intensity of
the light emitted must not be less than 1.0 cd.

7.4. In the case of a lamp containing more than one light source the lamp shall comply
with the minimum intensity required when any one light source has failed and when
all light sources are illuminated the maximum intensity shall not be exceeded.

A group of light sources, wired so that the failure of any one of them causes all of
them to stop emitting light, shall be considered to be one light source.

Illumination surface:

The area of the apparent surface in the direction of the axis of reference of the lamp
shall be not less than 25 cm² and not more than 200 cm².

Colour of light.

The colour of the light shall be white.
...
The colour must be within the limits of the trichromatic co-ordinates:

TRICHROMATIC COORDINATES

WHITE

Limit towards blue X > 0.310
Limit towards yellow X < 0.500

Limit towards green (Y < 0.150 + 0.640 X
(Y < 0.440

Limit towards purple Y > 0.050 + 0.750 X
Limit towards red Y > 0.382

CORNER POINTS X Y

0.310 0.348
0.310 0.283
0.443 0.382
0.500 0.382
0.500 0.440
0.453 0.440

So light distribution minimums I've plotted below:

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And color requirements plotted at CIE 1931 diagram:

Now I'll be appreciate for any help because I'm a newbie in it.

1. Choosing of LED and optics.
1.1. I choose Cree XP-E/G LEDs since it's commonly used and there are a lot of optics for it.
1.2. Ledl optics look like smart choice between price and quality. FA11116 LXP-O-90, FA10662 LXP-REC and FA10669 CXP-O have a proper distribution for our module. In numbers its:

LXP OVAL FA11116_LXP-O-90 ±5° x ±21° 
LXP RECTANGULAR FA10662_LXP-REC  ±20° x ±11° 
CXP SQUARE OVAL  FA10669_CXP-O  ±7° x ±23° 

LXP-G OVAL FA11116_LXP-G-O-90 ±19° x ±10.5° 
LXP-G RECTANGULAR FA10662_LXP-G-REC  ±19° x ±11.5° 
CXP-G SQUARE OVAL FA10669_CXP-G-O ±21.5° x ±6.5°

I prefer wider vertical distribution, so rectangular lens looks very interesting.
Carlco has interesting lenses also, but doesn't specify vertical distribution in this PDFs and are more expensive.

CXP and LXP lenses square are about 4,6 cm^2, so I need at least in 6 of it (25/4.6 = 5.4).

Each lens costs about 3$, each XP-E/G costs 4-6$, so optical part of each module costs about 54$.

Since it looks like a little bit expensive for me and using XP leds some kind of overkill (in terms of intensity), could anybody say are there some LED and optics cheaper than that? Or I'm wrong and it's normal price?

P.S. Already manufactured DRLs in Europe which I knows:
1. Hella with this LEDay and LEDay FLEX
2. Philips DRL

Hella LEday has very unusual reflector:

 

[2009Prius]

Great info! Any update on the actual project? Thanks!

 

[Xplorer]

It seems that you are designing a 'direct fire' type of LED DRL.

The one at the bottom of the page uses an indirect LED arrangement, it likely does not use lens optics.

How are you going to check the light distribution when you are done?

 

[tay]

It seems that you are designing a 'direct fire' type of LED DRL.

The one at the bottom of the page uses an indirect LED arrangement, it likely does not use lens optics.

How are you going to check the light distribution when you are done?

Probably find a nice empty wall, make marks at all test points using trigonometry and a tape measure, then use a handheld photometer at each point. That's how I would do it, at least.

 

[RusDyr]

Xplorer, we bought Ledil lenses, which specify proper distribution. Light is quite visible, believe me. ;) However, we are going to check it by flashmeter in University lab.

2009Prius, no news yet - we are waiting our shipped XP-G from Australia. :(

 

[RusDyr]

A bit of proof-of-concept's photos.
Have used Ledil LXP-REC and Ledil CXP-O lenses, 3xXP-G R5 in aluminium |_|-viewed chasis, powered by one 3.7 Li-Ion battery.



Have tested with simplest LM317-based current regulator, works fine in 3p mode (in 3s mode LM easy overheated).

Have found a many lacks of design :/

Needs in normal case (probably one per LED, not a linear for all), Hi/Lo (PWM or hardware switching?) driver.

And still looking for investor, yep :)