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SAE TECHNICAL
PAPER SERIES 2000-01-0801

Utilizing CFD for Thermal Analysis

of a Prototype HID Fog Lamp
William I. Moore and Christopher R. Powers
Guide Corporation

Reprinted From: Automotive Lighting Research

(SP–1531)

SAE 2000 World Congress

Detroit, Michigan
March 6-9, 2000

400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760
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2000-01-0801

Utilizing CFD for Thermal Analysis of a Prototype

HID Fog Lamp
William I. Moore and Christopher R. Powers
Guide Corporation

Copyright © 2000 Society of Automotive Engineers, Inc.

ABSTRACT A. Develop an accurate HID light source thermal model

B. Perform thermal analysis of an HID fog lamp to verify
An advanced high intensity discharge (HID) light source that the predicted temperatures were below the lamp
thermal model has been developed and used to analyze material deformation limit.
heating problems in a HID fog lamp. The HID thermal
model incorporates coupled specular radiation and Advanced methods for thermal modeling of a fog lamp
natural convection to accurately predict the HID capsule with an HID light source are discussed in the following
surface temperatures. The HID light source model was sections. The accuracy of the HID light source thermal
used to predict fog lamp lens and housing temperatures model is verified by temperature measurements. The
and to provide critical information regarding material impact of the predicted lamp temperatures on the
specifications. The development of a HID light source material selection for the lens and housing are also
model is a major step forward in the use of predictive discussed.
tools for the thermal analysis of automotive exterior
lighting. 2.0 MODEL DESCRIPTION

1.0 INTRODUCTION A. FOG LAMP – The fog lamp thermal model shown in
Figure 1 includes the HID light source, the nickel/chrome
The capability to accurately predict automotive lamp plated bulb shield, the reflective coating, the lamp wall,
temperatures is an important step in optimizing material the plastic lens and the internal air volume. The lamp
selection and lamp geometry while reducing the need for inner surfaces absorb, transmit and reflect radiation both
costly prototypes. Thermoplastic and thermosetting specularly and diffusely. The aluminized surfaces were
materials such as polycarbonate have low temperature modeled as mirror-like specular surfaces. The lamp
limits relative to glass. Therefore, identifying thermal surfaces are heated by direct radiation from the HID arc
problems before prototype hardware has been developed and by re-radiation from the outer glass surface. The
is critical in order to select the optimum lamp materials. radiation is coupled with heating from lamp air natural
convection. The bulb shield absorbs heat from the HID
A high intensity discharge (HID) fog lamp thermal model light source and re-radiates to the reflector and lens.
was developed as part of an analytical design study The bulb shield is black on the inside and has a specular/
without the use of prototype hardware. Comparisons diffuse outer surface finish with a high reflectivity.
between predicted and measured temperatures for Conjugate heat transfer couples the convection and
verifying the accuracy of a headlamp thermal model have conduction through the solid wall of the bulb shield and
been verified in a previous paper [1]. The HID fog lamp
thermal analysis was performed using the ADINA-F finite
element computer code. ADINA-F is a computational
fluid dynamics (CFD) modeling code that solves for
combined specular radiation and natural convection [2]. A
specular radiation method is required to accurately model
the highly reflective, metalized surfaces used inside
automotive exterior lighting. The thermal analysis was
based on a 35-Watt HID light source and a fog lamp with
housing, lens, reflector and bulb shield.
The following steps were performed to develop a model
for predicting HID fog lamp temperatures. Figure 1. HID Fog Lamp Geometry (Rear View)

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housing. A viscous incompressible flow model with glass envelope. The HID light source is more complex
temperature dependent air properties was used for the than the typical halogen bulb and requires a more
lamp internal air volume. Figure 2.0 shows the fog lamp sophisticated model to accurately predict the light source
lens and housing outer surface finite element mesh and temperature. The discharge light source utilizes a high
Figure 3 shows a cross sectional view of the air volume voltage arc to produce light whereas the halogen bulb
and solid wall mesh. Approximately 200,000 3D produces light by heating the tungsten filament. Heating
tetrahedral elements were used to represent the air and of the light source is a result of radiation absorption,
solid wall regions and 6,000 surface radiation faces were convection and conduction.
used for the specular radiation model. A refined mesh
One of the advantages of using a HID light source as
was used near the HID capsule outer surface to
opposed to a tungsten-halogen bulb is the increase in
accurately model the high velocity and temperature
visible light output relative to the infrared energy
gradients which occur in this region.
produced. This results in a lower amount of infrared
absorption by the HID capsule and the fog lamp lens.
The increased efficiency in light output is due to the much
higher operating temperature for the HID source which is
near 4200 °C, compared to the tungsten halogen filament
temperature of 3200 °C. The effect of operating
temperature on visible light output is shown in Figure A-1
of Appendix A. For the HID light source, over 30% of the
total energy is radiated in the visible/UV region compared
to only about 10% for the tungsten halogen. The
increased efficiency reduces the amount of radiation that
is absorbed by the lens.
In addition, the HID outer glass envelope temperature is
reduced by the use of a fused quartz material. The
quartz blocks UV radiation while transmitting a higher
percentage of the near IR radiation than is the case for a
glass material. The fused quartz spectral transmission
characteristics are shown in Figure A-2 of Appendix A.
Figure 2. HID Fog Lamp Surface Mesh (Side View) The basic features of the HID Light source model are
summarized as follows:
• Arc heating radiation based on 35-Watt power input
• Transmission and absorption of radiation in the inner
and outer fused quartz glass capsules (Visible and
IR)
• Conduction in the electrodes and fused quartz glass
• Natural convection heating in the inner and outer
capsules
• Thermal conduction in the electrodes

Figure 3. Fog Lamp Air Volume Mesh (Side View)

B. HID LIGHT SOURCE MODEL – Unlike tungsten-

halogen bulbs which emit energy (UV, visible and infrared
light) from a heated filament, HID bulbs emit energy from
a high voltage arc passed through a gas between two
electrodes. Figure 4 shows the basic components of the
35-watt light source, consisting of tungsten electrodes,
pressurized fused quartz inner capsule and an outer Figure 4. HID Light Source

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C. SPECULAR RADIATION THEORY – The HID light The external surface heat transfer coefficient was
source and fog lamp thermal models were solved using calculated using the Churchill and Chu correlation [4] as
the ADINA-F specular radiation model. The specular shown in equations 6 through 8.
radiation model accounts for transmission, specular and
diffuse reflection, radiation absorption and surface 0.67 Ra1 / 4
Nu = 0.68 +
emissivity. Specular radiation is defined as a surface
where radiation is reflected at the same angle at which it
[1 + (0.492 / Pr) ]
9 / 16 4 / 9
(6)
is incident.
gβ (Ts − T∞ ) L3
Ra = ⋅ Pr
θi = θ r ν2
(1) (7)
This is the case for an aluminized reflector in a headlamp k
h = ⋅ Nu
for instance. D (8)
At a surface energy is absorbed, transmitted and
reflected. Energy is also emitted from the surface based 3.0 RESULTS
on the surface temperature and emissivity. Therefore,
the net heat flux into a surface due to radiation is given A. HID LIGHT SOURCE THERMAL MODEL – The HID
by: light source and fog lamp temperature predictions are

( )
shown in Figures 5 through 7. Figure 5 shows the
q = ε G − σT 4 predicted HID arc source temperature of 4200°C based
(2)
on a 35-Watt input. Figure 6 shows the predicted HID
where ε is the surface emissivity, and G is the incident capsule outer surface temperature of 607°C, which
radiation that is absorbed by a surface. To simplify the occurred directly above the arc. This correlates well
material property definitions, a gray body assumption is with the HID capsule manufacturer’s temperature
made which equates the surface emissivity and its measurement of 588°C [5]. The predicted temperature
absorptivity: at the base of the HID outer capsule was 320°C
compared to a measured temperature of 345°C. The
ε =α (3) predicted inner capsule temperature is shown in Figure 7.
The radiation energy is combined with the convective The HID light source thermal analysis results are
energy in the following manner. The net absorbed energy summarized in Table 1.0.
from equation 2 is added to the source term qB in the
global energy equation shown below for reference [3]: Table 1.0 HID Thermal Model Results

(
∂ ρc p T ) + (ρ )
Location Predicted Measured Error
v j T + q j , j = q B + 2 µeij eij
∂t (4) Arc 4200 NA
A B C D Outer Capsule (Center) 607 588 + 3%
The term labeled A above represents the transient heat Capsule Base 320 345 - 7.8%
capacitance. Because the analysis presented here is a
steady state condition, the A term is eliminated. The B
term combines the effects of convection form the surface
and conduction in the solid wall. Term C is the source
term described above. The D term represents viscous
effects in the air.

D. NATURAL CONVECTION – The lamp air natural

convection was analyzed using a viscous incompressible
flow model with temperature dependent viscosity and
thermal conductivity and a constant density. The
Boussinesq approximation was used to model the
temperature induced density variations that create the
natural convection airflow. The lamp outer surface
dissipates heat by radiation and convection to the room
temperature air. Boundary radiation was handled in the
same way as described above.
Boundary convection was modeled using: Figure 5. Predicted Arc Source Temperature
Qconv = h(Ts – Tamb) (5)

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Figure 7. Predicted HID Inner Capsule Temperature

Figure 6. Predicted HID Outer Capsule Temperature
Localized heating of the reflector is primarily the result of
B. FOG LAMP THERMAL MODEL – The steady state hot air impinging on the lamp inner surface as it circulates
thermal analysis was run for the fog lamp in order to from the HID capsule to the bulb shield and reflector. A
determine the maximum temperatures for the reflector, significant temperature gradient occurred across the
lens, bulb shield and housing. The results obtained from lamp wall which means that the lamp wall thickness is an
the case in which a bulb shield was installed in the fog important design parameter relative to the wall
lamp are shown in Figures 8 through 11. Figure 8 shows temperature. A summary of the predicted fog lamp
the predicted maximum lens outer surface temperature of temperatures is shown below in Table 2.0
166°C. Figure 9 shows the maximum housing outer
surface temperature of 163°C and Figure 10 shows the Table 2.0 HID Fog Lamp Temperature Predictions
maximum housing inner surface temperature of 191°C.
The predicted lens temperature exceeded the allowable Location Temperature °C
deformation temperature of 149°C for polycarbonate. Lens Inner 174
The predicted reflector temperature of 191°C requires
Lens Outer 166
the use of a high heat thermoset material such BMC.
Figure 11 shows the bulb shield temperature distribution Housing Inner 191
with a maximum of 426°C. A plot of the lamp internal air Housing Outer 163
velocity profile is shown in Figure 12. A strong coupling
exists between the natural convection airflow and the Bulb Shield 426
lamp inner surface temperatures. The maximum air
velocity was approximately 20 centimeters per second
and occurred directly above the HID light source. The Since prototype hardware was not available at the time of
analysis was performed for a closed volume without this study the temperature predictions have not been
using any vent holes. The effect of vent holes on lamp correlated with test results. Temperature correlation will
temperature is considered to be insignificant. be the subject of future investigation.

Figure 9. Predicted Housing Outer Surface

Figure 8. Predicted Lamp Lens Outer Surface Temp Temperature

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radiation characteristics for the HID materials, an

accurate thermal model was developed for the HID light
source. The predicted temperatures for the outer
capsule were accurate within 10% of temperature
measurements which were provide by the manufacturer.
Lens and housing temperature predictions were obtained
using the HID light source model coupled with specular
radiation in the lens and reflector and lamp internal air
natural convection. The fog lamp lens temperature
predictions showed that lens temperature of 166°C
exceeded the allowable polycarbonate deformation
temperature of 149°C. Therefore, a high heat lens
material must be used.
The predicted reflector temperature of 191°C also
precludes the use of a polycarbonate housing; therefore,
a thermoset material such as BMC should be used.
Figure 10. Predicted Reflector Surface Temperature More research is required to determine the effect of high
along a Vertical Cross Section temperatures on the reflector coatings.

5.0 CONCLUSIONS

Using advanced CFD tools with specular radiation and

natural convection combined with spectral analysis, a
HID light source thermal model has been developed and
validated to within 10% of temperature measurements.
The energy-based method using power input provides
the capability to model direct radiation from the HID arc
source to the fog lamp lens and housing. HID capsule re-
radiation and lamp internal air heating can be solved
simultaneously with the arc radiation. Spectral analysis
can be used to predict the energy distribution in the UV,
visible and infrared wavelength regions.
Figure 11. Predicted Shield Surface Temperature Although the HID light source is more efficient than the
tungsten halogen bulb, packaging and lamp geometry
are still critical in lamp thermal performance. The use of
a bulb shield may contribute to lamp heating due to the
high shield temperature of 426°C. The shield absorbs a
large amount of radiation and this heat must be removed
without causing excessive reflector and lens heating.
The shield chosen for this fog lamp design is considered
to be a major contributor to the high reflector
temperatures. The recommended solution to the fog
lamp heating problem is to use a high heat lens material.

ACKNOWLEDGMENTS

The author wishes to thank Mr. Joseph Jaklic of the

Guide Research and Development Group for his
invaluable contributions in developing the HID light
source thermal model.
Figure 12. Predicted Lamp Internal Air Velocity
REFERENCES
4.0 DISCUSSION
1. William I. Moore and Christopher R. Powers,
The ADINA-F code was utilized to develop a HID fog “Temperature Predictions for Automotive Headlamps
lamp thermal analysis model that is based on an energy using a Coupled Specular Radiation and Natural
balance method. Using a spectral analysis method Convection Model” 1999 SAE International Congress
based on power input and wavelength dependent and Exposition, Detroit, MI, 1999

5
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2. ADINA-F Version 7.1.3, ADINA R&D Inc., Watertown, 1.10

3. ADINA Theory and Modeling Guide Volume 2, 1.00

Fraction of Total Emitted Radiation

Report ARD 97-8, p.119, ADINA R&D Inc., 0.90

Watertown, MA, 1997 0.80

4. Churchill, S.W., and H.H.S. Chu: Correlating 0.70

Equations for Laminar and Turbulent Free Convection 0.60

HID ARC
from a Vertical Plate, Int. J. Heat Mass Transfer, vol. 0.50
Tungsten Halogen
18, p.1323, 1975. 0.40

5. Philips Automotive Lighting, Unternehmensbereich 0.30

der Philips GmbH, Gluhlampenwerk Aachen, 1998 0.20

0.10

DEFINITIONS, ABBREVIATIONS 0.00

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6
Wavelength (microns)

CFD Computational Fluid Dynamics Figure A-1. HID Light Source Spectral Energy
Distribution
HID High Intensity Discharge
FEA Finite Element Analysis
Figure A-2 shows the transmissivity vs. wavelength for
IR Infrared fused quartz. The fused quartz shows transmits about
UV Ultraviolet 90% of radiation below 3.5 µm and also absorbs most UV
µm Microns radiation. The characteristics of glass differ slightly since
°F Degrees Fahrenheit the transmissivity of glass decreases significantly above
°C Degrees Celsius 2.5 µm.
α Absorptivity
ε Emissivity
σ Stefan Boltzman Constant
q Heat Flow
ρ Density
v Velocity
eij Components of Velocity Strain Tensor
µ Viscosity
Cp Specific Heat
G Incident Radiation
θ Radiation Ray Angle
T Ambient Temperature
A Surface Area
Qrad Radiated Energy
Qconv Convected Energy
Nu Nusselt Number
Ra Raleigh Number
Figure A-2. Transmissivity vs. Wavelength for Fused
Pr Prandlt Number Quartz

APPENDIX A

Figure A-1 shows the spectral energy distribution for a

HID light source and for a tungsten halogen filament.
The HID source operates at near 4200°C where the
tungsten filament operates at about 3200°C. Therefore
the radiated energy for the HID is shifted toward the
visible region of the spectrum (0.4 to 0.7 µm).