A numerical model was developed to design a new automotive low-beam light-emitting diode (LED) headlamp. First, an existing automotive low-beam projector LED headlamp model with ray-tracing software (TracePro) was simulated. The existing commercially available automobile LED headlamp is a combination of one multi-reflector and two projection systems serving as a lowbeam LED headlamp module. The simulated results were compared with the headlamp regulations to prove that the headlamp numerical model and boundary conditions were correct and similar to reality. Finally, the original design was modified into only two projection systems using singlelightoutput 515 lumen LEDs. Each projection system was improved to make the headlamp light distributions conform to the ECE R112 regulation. It was concluded that using a high power LED could decrease the number of optical systems required for an automotive headlamp.
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