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Automotive Headlight Upgrades – Part 2: Terminology

Light Terminology

We talked about headlight bulb styles in the first part of our series on understanding headlight upgrades. In this article, we will briefly explain relevant light terminology to help you understand what lumens, lux, candela and watts mean. Knowing what these terms mean will help you make better bulb upgrade choices – and you’ll be less likely to be fooled by bogus light output claims.

The Importance of Proper Headlights

The forward lighting system on your car or truck is, or at least should be, designed to light up the road in front of your vehicle. The lighting should be bright enough to allow you to see and react to objects in your path safely. If your car needs two seconds to stop from 40 miles per hour, then your lights need to illuminate objects at least 117 feet in front of your vehicle.

Light Terminology
Rally racers add extra lights to their race cars to see better at night. Image: FIA World Rally Championship

The Candela

Long ago, a light source’s output was comparable to the light produced by a typical wax candle. A conventional wax candle produces 1 candela (symbol: cd) of light. It’s crucial to understand that this is the total light output of the light source in all directions. Put another way, no matter what direction you’re looking at a candle from, it produces 1 candela or 1 cd.

Light Terminology – Lumens

A lumen (symbol: lm) is the most commonly used descriptor of how much light a bulb produces. The lumen is the SI unit used to quantify luminous flux. Sadly, it’s also easy for this number to be irrelevant in describing how well you can see in front of you at night.

We have to detour a moment to make a super-technical definition. The term steradian, or square radian, describes a circular area on the surface of a sphere. A sphere (or ball) has a surface area of 4π steradians – or 12.5664 steradians. Expressed another way, 1 steradian is 1/12.5664 of the surface of a sphere. If you have a sphere with a radius of 2 meters, then 1 steradian represents 4 square meters on the surface of that sphere. It should be no surprise, then, that the total surface area of the sphere is 50.265 square meters and that 1/12.5664 of that is 4 square meters.

Light Terminology
A graphical representation of 1 steradian. By Andy Anderson – Own work, CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=84111964

OK, now back to the lumen. One lumen equals 1 steradian of a sphere illuminated by a light source that outputs 1 candela. Think of this description as that of a flashlight pointing at the inside of a sphere. If the flashlight produces 1 candela of output and all the light is focused onto an area the size of 1 steradian, the result is 1 lumen of illumination.

If we back up and consider the light source to be isotropic or equal in output in all directions, then the light source must produce 12.5664 candelas to produce 1 lumen of flux over an area of 1 steradian. In theory, you need about 12 and a half candles to produce 1 lumen of luminous flux on an area of 1 steradian of a sphere with a radius of 1 meter. A 1-candela light source would produce 1/12.5664 of a lumen on the same area, or 0.0796 lumen.

When professional light bulb manufacturers measure a light source’s output, they use an integrating sphere. The inside of the sphere has a pure white reflective coating. The goal of the sphere is to average out any bright or dim spots to create an even distribution of light through the assembly. A calibrated electronic sensor measures the light level in the sphere to calculate the total light provided by the light source.

Light Terminology
A light-integrating sphere accurately measures the output of light sources. Image: Pro-Lite Technology Ltd.

When a company like Cree or Samsung creates an LED, they describe the output of the LED COB in lumens, or more accurately, lumens per watt (LPW). A high-quality LED COB produces about 133 lumens of output per watt. Most high-power LED COBs have a maximum power handling of about 3 watts. This efficiency means a 1-watt single LED COB can produce about 400 lumens. An aftermarket LED headlight bulb that uses one of these LED COBs on each side would produce 800 lumens. Compact assemblies with three or four COBs assembled into a single housing are available. These 12-watt LED COBs produce about 1,500 lumens. If a 12-watt COB is on each side of the bulb, it would theoretically produce 3,000 lumens.

Light Terminology
The ATOM bulbs from Lumens High Performance Lighting are rated to produce 3,000 lumens of “total raw light output.”

Light Terminology – Lux

Unfortunately, having an incredibly bright light bulb doesn’t directly correlate to proper road lighting. Understanding lighting terminology is crucial. The plastic lens on the front of the light assembly blocks a small amount of light. The design of the reflector at the back of the light assembly plays a considerable role in determining where that light projects. In a worst-case example, you could have a 3,000-lumen headlight bulb in a black box, and no light would be visible and, as such, the bulb would produce 0 lux.

Lux (symbol: lx) is the SI unit of luminous flux per unit area. The lux is the unit that quantifies light intensity as the human eye perceives it. Thankfully, unlike the whole steradian thing (sorry about that), the lux uses an area of 1 square meter. One lux equals the illumination of 1 lumen of light over 1 square meter. If all the light from a 100-lumen light source illuminates 1 square meter, the light intensity would be 100 lux.

Light Terminology

How do all these numbers relate to headlight bulb ratings and how well you can see the road once the sun sets? With modern LED headlights like you’d find on an Audi, Mercedes-Benz or Genesis, the optics are designed to work specifically with the LED COBs light emission pattern. Every aspect of the light source is optimized to produce a specific beam pattern on the road. If you upgrade your headlights from a halogen bulb, HID or LED aftermarket bulbs must work with the existing reflectors and lens. The upper cut-off for the low beams must be accurate, and the light distribution pattern needs to remain the same. These criteria are crucial for your safety and the safety of those you share the road with.

Light Terminology
The Genesis G70 sedan features LED headlights. Image: Genesis.com

Companies such as Rigid Industries and Baja Designs that manufacture aftermarket off-road and work light solutions provide light output levels in lux. Both companies describe the distance from the light where they produce a fixed illumination level. Of course, the two companies don’t use the same descriptions, so you have to do some “figurin’” to determine which is best for your application.

Light Terminology
Extreme Audio near Richmond, Virginia, upgraded this Mercedes-Benz Sprinter with a Baja Designs LP6 PRO amber light pod set.

Watts, Power and Light Output

The SI unit watt describes the work done over a fixed time – usually one second. One amp of current flowing through 1 ohm of resistance in electrical circuits produces 1 watt of heat energy. To calculate watts in direct current (DC) circuits, you can multiply the voltage times the current. If you apply 12 volts to a light bulb and 2 amps of current flow through the circuit, then the work done is 24 watts.

When all we had were halogen bulbs, a bulb that drew more energy would typically produce more light. The low beams on most cars and trucks used 35-watt bulbs, and many used 55-watt bulbs for the high beams. Unfortunately, those numbers don’t correspond to light output regarding HID and LED replacement bulbs. A 15-watt LED bulb produces significantly more light than a 35-watt halogen bulb. Many HID kits were marketed with 35- or 55-watt ratings, making three or four times as much light as halogen units. The bottom line is that looking at HID or LED headlight upgrades and comparing them by the energy they consume won’t be effective.

Light Terminology
Morimoto Elite HID kits are available in 35- or 50-watt configurations. Image: The Retrofit Source.

Research Your Headlight Upgrades

A forward lighting system that functions accurately and reliably is the top vehicle safety consideration once the sun sets. If your headlight bulbs are worn out, the lenses are foggy, or the lights aren’t aimed properly, your risk of getting into an accident increases dramatically. Now that you understand automotive headlight terminology better, you can make better purchasing decisions. Drop by a local specialty mobile enhancement retailer today to find out about the upgrades they have available to improve the lighting system on your vehicle.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Lighting, RESOURCE LIBRARY

How Do I Know if My Car Audio DSP Is Adjusted Properly?

DSP Adjustment

It should go without saying that a car stereo system designed around multiple amplifier channels and a DSP is the easiest way to get great sound in your vehicle. The technician working on your vehicle has complete control over the output level, sound arrival time and the frequency response of each speaker in the system. The result should be a sound system that is as optimized as possible – assuming the calibration process is executed properly. There are still many misunderstandings about what a DSP can and can’t do. This article will provide a few things to listen for to help you determine whether your DSP has been adjusted properly.

What Is a DSP?

What is a digital signal processor? Though we have covered the topic extensively, we’ll offer a quick “too long; didn’t read” for those new to our magazine. A DSP is a computer chip optimized to perform many calculations quickly and repeatedly on a sequence of digital samples. These samples are typically a digital representation of an analog signal. In the case of our car audio systems, the analog signals are the left and right channels of the audio recording. DSPs are common in other applications, including video processing and radio frequency transmission analysis. Modern recording studios and live venues use DSP-based mixing consoles.

DSP Adjustment
Escort’s M14 radar receiver uses an Analog Devices Blackfin DSP to pick out police radar signals and reject noise.
DSP Adjustment
The Vista One Carbon is a high-end DSP-based mixing console ideal for live, broadcast and studio applications.

How Is a DSP Used in Car Audio Systems?

In car audio applications, a DSP serves many purposes. A DSP can combine signals from multiple sources, adjust levels, apply equalization and frequency filtering, and add delay to a signal. In short, it helps the technician connect to a factory-installed stereo, optimize the signal to each speaker and compensate for your vehicle’s acoustics.

If your car stereo uses an aftermarket head unit, your installer will likely connect a DSP directly to the radio’s preamp outputs using RCA cables. Suppose you have a vehicle that uses a digital interface between a factory-installed head unit and an amplifier like A2B, MOST, AVB or a SP/DIF connection. In that case, you may have an interface that feeds a digital signal to your DSP over a fiber-optic cable. Finally, many audio system upgrades require recombining signals from multiple factory-installed amplifier channels and removing any processing to create a full-bandwidth signal. A high-quality DSP can help with this.

After the audio signal is in the DSP, the first order of business is to route that signal to the appropriate output channels. You don’t want the left-channel signal from the radio going to the right-side tweeter. Also, you’ll likely want the signals from both the left and right channels going to the subwoofer signal. All reputable DSPs have a signal-routing mixer to perform these tasks.

Next, the technician configuring the system must filter the signals to each speaker. You don’t want bass information going to a tweeter or midrange information to a subwoofer. A properly trained technician knows which high- and low-pass crossovers to apply to the speakers in your vehicle based on their design, directivity characteristics and the speakers that are operating in adjacent frequency ranges.

The last step is for the technician to use a calibrated microphone system and measure each speaker’s acoustic output at the listening position. Using that information, they can adjust the equalizer to smooth out any peaks or dips caused by reflections in the vehicle. Finally, the output level of each speaker is adjusted to ensure that the transition from one driver to another is smooth.

DSP Adjustment
The Audison bit-Tune is an acoustic real-time audio analyzer that uses a microphone array to capture accurate information.

Auditioning Overall Tonal Balance

While a DSP often seems like some mystical black box of audio voodoo, they are quite simple devices. Yet they do have an extensive list of functions and require training and a thorough understanding of the laws of physics to implement properly. A DSP is effectively mandatory if your goal is realism and accuracy from a car audio upgrade. That brings us to the question, how would a consumer know whether the DSP in their car or truck is adjusted properly?

The first thing to listen for is a smooth frequency response. There shouldn’t be emphasis or deficiencies in any frequency range. For example, if the letters S and T seem overly prominent, the equalizer bands around 3 and 5 kHz might need adjustment. If voices are boomy or chesty, there might be too much output around 200 Hz. The bottom line is that if every genre of music doesn’t sound right, then the DSP needs more adjustment.

An idea offered by long-time car audio competitor Harry Kimura is to listen to a well-engineered piano recording. The lowest note on a piano has a fundamental frequency of 27.5 hertz. That’s well below what an audio system without a subwoofer can reproduce with any authority. The highest note has a fundamental frequency of 4.186 kHz. It’s crucial to remember that each note includes several octaves’ worth of harmonics to give the instrument its “sound.” There’s still important audio information beyond 12 kHz from this 4.186 kHz note. If someone plays a scale from the highest to the lowest notes, each should be reproduced by your car audio system with the same volume or intensity. If something is too loud or quiet, the DSP’s equalizer needs adjustment.

DSP Adjustment
The Rockford Fosgate DSR1 DSP has eight output channels and includes an iDatalink Maestro AR interface.
DSP Adjustment
The bit Nove DSP from Audison includes six analog inputs, two digital inputs and nine outputs for extremely flexible audio system design.
DSP Adjustment
The compact ARC Audio PSM-Pro DSP includes audio processing features typically found only on high-end models.

What about the Bass?

We can confidently tell you that a car audio system that plays the bottom two octaves of a piano at the same level as middle C won’t be much fun on the road. It might be super-accurate, but the bass will be drowned out when competing with wind, road and exhaust noise. The subwoofer in your car audio system should be 8 to 12 dB louder than the midrange for the system to be enjoyable while in motion. If you’re a basshead, fill your boots!

The Source of Sound

The second criterion to listen for is staging and imaging. Imaging refers to the ability of an audio system to render the sound of specific instruments accurately on a virtual soundstage. Think of yourself listening to a live acoustic music performance. A four-piece jazz band with a drummer, pianist, upright bass player and lead singer would be a perfect example. No matter where you sit in the audience, the sound source from their instruments is easy to detect. You’d know if the lead singer walked across the stage while performing, even if you didn’t see them.

In your car audio system, you should be able to pick out the specific instruments in a well-recorded track. If the singer and drummer were in the center of the stage, they should sound like they are in the center of the dash or windshield. If the bassist is on the left, then the sound should come from in front of the steering wheel. If the piano was on the right side of the stage, it should sound like it’s coming from the airbag on the right side of the dash.

Here’s a good example of what you should hear if the system has a solid soundstage and good imaging. “Listen to Money for Nothing” by Dire Straits. At 1:12 into the track, Pick Withers’ drums pan from the far right to the center. Each drum appears to have a dedicated microphone, and their signals are panned to fill the soundstage. As he hits different drums, the sound source should move. The system isn’t configured correctly if the drums are a big blurry mess.

DSP Adjustment
Dire Straits’ Brothers in Arms album is a popular choice for auditioning high-end audio systems because of its excellent recording quality.

How Do You Want Your System to Sound?

The above description assumes you wanted your car audio system calibrated as though you were in the audience. The other option is to have the system configured as though you were on stage with the performance. In this scenario, the sound in your car would be more like what you’d hear when wearing headphones. The vocals and drums might be in the middle of your head. The bassist would be to your left, and the piano to the right. Some call this a “club” sound, where music comes from around you. The product specialist you’re working with to design your mobile audio system should ask you about your listening preferences during the client qualification process.

A car audio system with high-quality amplifiers and an excellent DSP will offer better focus for each instrument. We call this better imaging. We’ve heard many factory-installed audio systems where the center-stage vocals came from a space the size of a large pizza. The best aftermarket systems we’ve listened to reproduced that same track from a point in space the size of a tennis ball. It’s not just equipment that achieves this goal. The technician adjusting the DSP needs to know what to look for and what to ignore in the acoustic measurements to get this right.

DSP Adjustment
In the audience or on the stage – the shop installing your DSP must ask how you want the system configured. Image: mcmillanpazdansmith.com

What Can’t a DSP Fix?

There are some product and installation issues that a DSP can’t resolve. If you’ve chosen speakers with resonance and distortion issues, the DSP can’t remove that harmonic information added to your music. If you find the high-frequency response harsh or fatiguing, you are probably hearing harmonic distortion from your speakers. The only solution is to switch to better-designed speakers that include distortion-reducing designs and technologies.

The same goes for sloppy midbass. If a rim hit on a tom drum sounds like a thud or bump rather than a sharp crack, you may have a speaker or amplifier distortion problem. Audio components (primarily amplifiers and speakers) with high levels of intermodulation distortion typically cause muddiness or unwanted warmth in the lower midrange frequency range. No amount of DSP adjustment can fix this.

DSP Adjustment
An example of an exceptional intermodulation distortion measurement from a DSP-equipped car audio amplifier.

Learning About High-Quality Audio Systems and Accurate DSP Adjustment

This article kicks off a series on how to listen to audio systems and components from a technical perspective. We’ve noticed that many consumers think certain products “sound really good” when they are, at best, mediocre. We hope that educating everyone about what to listen for when auditioning speakers and listening to demo vehicles will help people purchase solutions that offer the best performance possible for their investment. As you learn what high-quality car audio upgrades sound like, use that information when working with a local specialty mobile enhancement retailer to pick the best upgrades possible.
This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Car Audio, RESOURCE LIBRARY

Do I Need a Line Output Converter To Add a Car Amplifier?

Output Converter

We’ve talked at length about how car audio line output converters work and have even compared a few to see which sound best. We skipped over a discussion on whether a car audio amplifier upgrade needs a line-output converter. Let’s dive in!

What Does a Line Output Converter Do?

A high-quality line output converter serves three purposes. First and foremost, it can reduce the voltage from a radio or amplifier output to something acceptable on the preamp input of an amplifier. Second, it converts a bridge-tied load (BTL) signal to a single-ended signal that works with all amplifiers. Thirdly, it can provide a remote turn-on signal to activate an amplifier when you turn on a factory radio.

Most car audio amplifiers can only accept up to 5 or 6 volts on their preamp inputs. This voltage is equivalent to the output of an amplifier that produces a maximum of 9 watts of power into a 4-ohm load. Since most car radios can produce at least 20 watts, equivalent to just under 9 volts of signal, we need circuitry to reduce that level and not over-drive the input stage on the amplifier.

All car radios we’ve tested use the bridge-tied load speaker output configuration. This speaker driving method allows a radio to provide more power than a single-ended design without needing a dedicated switching power supply. If you’ve asked a technician to install an inexpensive or poorly designed amplifier, it will likely need a single-ended signal.

If you have a factory-installed radio in your car, truck or SUV, the chances of a wire going live only when the radio is on is quite unlikely. You’ll need a way to tell the new amplifier when it’s time to wake up and get to work. A good-quality line output converter can do that.

Modern Amplifier Features – Automatic Turn-On Circuits

If you look at most high-quality amplifiers on the market, you’ll see they include some sort of remote turn-on detection circuitry. Some of these circuits monitor the input connections on the amplifier for a presence of an audio signal. This is usually called a signal-detect turn-on circuit. Others look for the 55 to 6 volts of DC offset found on the output of BTL amplifiers as would be used in a car radio. These circuits are called DC offset or BTL detection solutions.

Output Converter
The DPower 1 from Hertz includes their ART Auto Turn On/Off Circuitry to simplify installation.
Output Converter
The XM-4ES from Sony’s Mobile ES line includes a switch that will activate the remote turn-on detection feature.
Output Converter
Rockford Fosgate’s Prime-Series R2-300X4 four-channel amplifier includes an Auto Remote Turn-On option.
Output Converter
X2-Series amplifiers from ARC Audio include both signal and DC offset detection remote turn-on circuits for maximum installation flexibility.

Car Audio Amplifier Differential Inputs

Decades ago, car audio amplifiers used the same single-ended RCA input circuitry as a home stereo receiver. Reputable car audio equipment manufacturers realized that switching to balanced differential circuitry inputs dramatically reduced the chances of ground loops that could cause unwanted engine noise in an audio system. This balanced input circuitry also helps eliminate any unwanted noise that the interconnect cables might have picked up as they run through the vehicle.

We’ve written a few detailed articles on the importance of balanced differential inputs and how to test an amplifier to make sure it has this feature. Don’t bother with amplifiers that don’t use differential inputs. You’re only asking for headaches and noise.

Too Much Preamp Voltage

It’s not often you hear the phrase “too much voltage” in the context of car audio discussions. With that said, if you feed too much signal to the RCA inputs on an amplifier, both the input and output can add huge amounts of distortion to your audio system. This distortion is called clipping.

Designing a car audio system upgrade requires an understanding of how the factory-installed audio system works. Your installer might need to take frequency response and amplitude measurements before recommending products. Some factory-installed subwoofer amplifiers can produce just shy of 40 volts of signal.

If you’re shopping for an amplifier to add to a factory-installed radio or amplifier, choose one that can accept a wide range of voltages. Some amplifiers have dedicated speaker-level input terminals. Others have a switch that attenuates the signal on the RCA jacks. Some DSP-equipped amplifiers have digitally selected input voltage ranges.

Output Converter
The Audison Forza AF M4D four-channel amplifier can accept up to 22 volts of signal on its speaker-level inputs.
Output Converter
Sony’s Mobile ES Amplifiers will accept up to 16 volts on the RCA jacks when set to their high-voltage range.
Output Converter
Rockford Fosgate’s Punch-Series P600X4 amplifier can accept up to 12V on the RCA inputs without any switches or adapters.
Output Converter
The Blackbird DSP amplifier from ARC Audio will accept up to 32 volts on the RCA inputs. Four input ranges are selectable in the ARC DNA software.

Questions To Ask When Purchasing Audio Upgrades

If you want to add an amplifier to your car audio system, you’ll want to ask the product specialist you’re working with some questions. Aside from everything we’ve suggested in our Buyers Guides, you need to know what accessories they plan to use for the installation. If they say you need a line output converter, ask what it would cost to move up to an amplifier that can accept the full signal from the source unit and turn itself on and off automatically without any adapters. The chances are good that the higher-quality amplifier won’t just simplify the installation but will likely sound better. If they insist a line-output converter is still required, ask why.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Car Audio, Driver Safety, New Category Name, PRODUCTS, RESOURCE LIBRARY, UTV Audio, Vehicle Security, Vinyl Graphics, Vinyl Wraps, Wheels and Tires, Window Tint

Automotive Headlight Upgrades – Part 1: Technologies

Headlight Technologies

If you pay attention, you’ll see cars and trucks on the road with white, yellow, blue and even purple headlight bulbs. Whether chosen for style or performance, hundreds, if not thousands, of options are available to upgrade the lighting on your car, truck or motorcycle. Some replacement bulbs look neat, some are brighter, some have unwanted side effects, and some perform poorly. Let’s kick off this series about automotive headlight technologies and upgrades with some history and a look at the different lighting designs used on vehicles.

Headlight Bulb Styles

If you’ve been around the block a few times, you know there are two basic types of headlight bulbs: sealed beam and composite light assemblies. Sealed-beam bulbs were introduced around 1940, providing automakers with a relatively high-performance, all-glass lighting assembly that included the bulb, reflector and lens in a single non-serviceable unit. The vehicle manufacturer only needed a secure mounting and alignment solution to deliver reliable lighting. Some quick research shows that the 2017 Chevrolet Express van was one of the last newly manufactured vehicles to use sealed-beam headlights.

headlight technologies
An example of a Sylvania H6054 Xtravision sealed-beam headlamp.
headlight technologies
The 2017 Chevrolet Express van is among the last new vehicles produced with sealed-beam headlamps. Image: Adrenalinemotors.ca
headlight technologies
The iconic quad headlights of the second-generation Mercury Capri. Image: Hemmings.com

Around 1983, the first composite headlight assemblies began to be implemented in new cars and trucks. These lighting assemblies use three injection-molded plastic pieces to serve as the body, reflector and lens. These lights are typically molded in shapes that flow with the vehicle’s contours. One instant benefit of these designs was that automobile manufacturers could improve vehicle aerodynamics and allow more leeway in vehicle styling.

headlight technologies
If ever there was a vehicle renowned for having massive headlights, it would be the 1986-93 Volvo 240. Image: 240turbo.com
headlight technologies
The instantly recognizable Subaru WRX “bug-eye” headlights found on 2000 through 2002 Subaru Impreza vehicles. Image: aprperformance.com

Composite light assemblies have replaceable bulbs that fit into a unit that includes a body, a reflector and a lens. When the bulb fails, it is removable from inside the engine compartment, often with minimal difficulty. The cool-for-its-time 1984 Lincoln Mark VII is believed to be the first production vehicle to use composite lighting.

headlight technologies
Most composite headlights have access panels in the engine compartment that allow the bulb to be changed easily. Image: Ifixit.com
headlight technologies
An example of a 9005 halogen headlight bulb from Sylvania.
Headlight Technologies
Credit goes to the 1984 Lincoln Mark VII for being the first production vehicle to use composite headlights. Image: Hemmings.com

The composite headlight evolved to include a dedicated projector assembly within the lighting fixture. There are claims that the projector assembly, which consists of a reflector, lens and often a cutoff shield or shutter, provides more efficient light output than a reflector-style. It’s probable, but the specific performance comes down to the engineer who designed the light.

Headlight Technologies
An example of a projector-style headlight from a late-model Mazda MX-5 Miata. Image: Hooniverse.com
Headlight Technologies
An example of several projector assemblies. These are commonly used in upgrades to reflector-style composite lights. Image: theretrofitsource.com
Headlight Technologies
This 2013 Subaru WRX STI features upgrade OEM-style HID projectors, bulbs and ballasts.

Headlight Technologies

Whether the vehicle has sealed-beam or composite lights, there are dozens of bulb shapes and sizes. Sealed-beam bulbs came in various round and square sizes. Some bulbs had both low- and high-beam filaments in the same assembly. Bulbs for composite lights are similar, though much more compact. These bulbs are also available with single or low/high designs in one assembly.

Headlight Technologies
Some bulbs have dual filaments to provide low- and high-beam solutions from a single package. Image: Sylvania-automotive.com
Headlight Technologies
A small selection of bulb types. There are more than a dozen popular mounting flange and connector options.

Many composite light assemblies have a single bulb with a single light source that handles low- and high-beam conditions. When you want to see farther down the road, you pull back on the light control stalk on the left side of the steering column, activating an electromechanical solenoid in the projector. The solenoid moves the shutter out of the way, allowing all the light from the bulb to illuminate the road.

Headlight Technologies
An example of a headlight projector with a motorized shutter to produce different light patterns for low- and high-beam operation. Image: Rennlist.com user virkdoc

The Evolution of Automotive Headlight Bulbs

Headlights have come a long way from oil lamps burning in large housings on the front of the vehicle in 1880. Though electric lights started becoming popular in homes around this same time, it wasn’t until after 1910 that electric lights on vehicles became popular. These “higher-performance” light sources quickly became a requirement for new vehicles.

Early incandescent headlamp bulb technologies didn’t differ much from the lights some vehicles still come with today. In an incandescent light bulb, a filament made from tungsten is enclosed in an airtight glass chamber. When electricity passes through the filament, it heats up and produces light.

Headlight Technologies
An example of a dual-filament incandescent light bulb for 1935 through 1939 Ford vehicles. Image: speedwaymotors.com

The next evolution was the halogen incandescent light bulb. According to several sources, halogen headlamps were developed in 1961 by a group of European light bulb and headlamp makers. Halogen lamps use the same filament design as a conventional incandescent bulb but have a small amount of a halogen gas like iodine or bromine added to the chamber. Adding these chemicals results in the filament burning brighter and producing a whiter light. It also resulted in a bulb design that lasted significantly longer than its simple incandescent counterparts.

Interestingly, these bulbs weren’t initially permitted in the United States as they were too bright and exceeded the government’s 37,500-candela output limit. In Europe, headlights could have an output of 140,000 candelas per side. The light output limit in the United States was raised to 75,000 per side in 1979. An extremely detailed outline for lighting requirements and limitations can be found in Federal Motor Vehicle Safety Standard (FMVSS) 108. If you ever want to geek out or have a thorough understanding of the laws that govern all vehicle lights, give FMVSS 108 a read.

Headlight Technologies
An example of a 9007-style Sylvania halogen headlight bulb. Image: Sylvania-automotive.com

The next evolution in lighting technology was the high-intensity discharge (HID) bulb. Rather than applying the direct battery voltage to a filament, HID lighting systems have an external ballast module that feeds high-voltage, high-frequency energy to a pair of tungsten electrodes enclosed in a glass chamber. The chamber is filled with a noble gas and a metal or metal salt. Light is produced as the voltage jumps from one electrode to another, like a welder’s arc. This type of light source is often called an arc lamp.

The benefits of HID bulbs include a whiter light than incandescent or halogen bulbs and a more efficient system. Xenon arc lamps are a specific kind of HID system that uses xenon gas in the bulb. Other chemicals like mercury vapor, metal halide and sodium vapor are common in commercial applications such as high-bay lighting, theatre and movie lighting, and film projectors. There are even HID lamps that use radioactive isotopes like thorium and krypton-85 to help make the arc initiation easier. Bulbs for automotive applications do not use these radioactive materials.

Headlight Technologies
An example of a Sylvania D1R HID headlight bulb with an integrated electronic igniter module. Image: Sylvania-automotive.com

A potential drawback of HID lamps is radio frequency interference. The high-output voltage of the ballast that drives the bulb (which can be over 400 volts) combined with a high switching frequency that can exceed 100 kHz can produce harmonic information that can affect both AM and FM radio reception. Many less-expensive aftermarket HID upgrade kits have this interference problem.

Headlight Technologies
An example of an inexpensive aftermarket HID headlight upgrade kit with ballasts and bulbs.

Light emitting diode (LED) headlights are another newer technology that has provided several options to vehicle manufacturers. LEDs are solid-state semiconductors that emit light photons as electrons flow through the device. Early LEDs were expensive, costing hundreds of dollars per lumen of light output. Improvements and advancements in materials, production quantity and design have evolved so that LEDs now cost hundredths of a cent per lumen.

An important benefit of LED lighting technology is that it’s quite efficient. These lights are also incredibly compact and last tens of thousands of hours. LED lights reach their maximum output level almost instantly, whereas halogen bulbs take a part of a second, and HID bulbs can take several seconds. This instant illumination makes LEDs ideal for turn signals and brake lights where every millisecond matters in an emergency. Studies have shown that LEDs can save more than a tenth of a second in warning other drivers. When moving at 65 miles per hour, one-tenth of a second represents a distance of 9.53 feet. That’s significant. The compact size of LEDs allows automakers to get creative with styling, as the space needed to produce adequate light output on the road is minimal.

While LEDs are efficient, they are small and remain sensitive to heat. You will note that LED lighting assemblies include large heatsinks to ensure that the individual LED chips don’t overheat.

Headlight Technologies
Many cities and towns have switched to LED street lighting, which consumes significantly less power. Image: gecurrent.com
Headlight Technologies
A fan-cooled aluminum heatsink designed for a 100-watt, 8,000-lumen LED chip.

A drawback of aftermarket LED bulbs is that they haven’t historically been able to place the light source in the same location as an incandescent or HID bulb because of the need for the heatsink. This limitation can reduce the effective light output of the assembly because the reflector or projector optics might not be optimized properly. The only way to know if an aftermarket LED bulb will work in your vehicle is to test it before purchasing.

Headlight Technologies
An example of a LED headlight from a 2023 Hyundai G70 sedan. Image: motor1.com
Headlight Technologies
An ATOM LED replacement headlight bulb from Lumens rated accurately at 3,000 lumens of light output.

It’s worth noting that the little orange or yellow LED chip you see on each side of an aftermarket LED bulb is an array of multiple LED elements. These are called chip on board LEDs, or more commonly, an LED COB. A single COB includes dozens of individual LEDs mounted on a thermally efficient substrate and covered by a phosphor coating designed to produce a specific light color.

Headlight Technologies
An example of an LED COB that includes many LED elements in a single housing.

The latest technology in automotive lighting is lasers. Companies like Audi, BMW and Mercedes-Benz offer laser-equipped high beams on several vehicles. These lights use a solid-state laser diode to shoot an intense blue light at a yellow phosphor. The phosphor is similar to the yellow rectangles you see in LED lights. Reflectors and lenses can then direct the output of this light source to illuminate the road.

The benefit of laser light solutions is that they are even more compact and energy-efficient than LEDs. Production vehicles first implemented laser headlights in 2014. Laser high beams can illuminate up to 600 meters in front of a car or SUV. Because of the intensity of the laser light sources, active light control technologies help ensure that oncoming drivers aren’t blinded.

Headlight Technologies
With four times the light output of LED bulbs, laser headlights manufactured by OSRAM are ideal for high-beam applications.
Headlight Technologies
The utterly bonkers all-electric Audi S1 Hoonitron features laser lights to ensure maximum visibility at insane speeds.

Light Brightness and Other Lies

Just as with incredibly overstated amplifier and speaker power ratings, the aftermarket lighting industry has fallen prey to completely bogus light output claims. I can tell you with the utmost confidence that a single 9005 LED bulb with two chips will not produce 22,000 lumens of light output.

To understand the math behind the above statement, a state-of-the-art LED COB can produce about 400 lumens of light with 1.6 amps of current. LED intensity is controlled by how much current flows through the device. So, to produce 22,000 lumens of light, the bulb would need to draw 88 amps of current.

The specifications provided with these so-called 22,000-lumen LED bulbs note that they use 80 watts. At 12 volts, that’s 6.67 amps of current. A more appropriate light output claim would be about 1,670 lumens if they used the highest-performing LED COBs available. Oh, one last note: Many aftermarket LED bulb manufacturers quote the light output from the pair of bulbs. So, the “bogus factor” can be divided in half and still be impossible. As always, buyer beware, and don’t believe everything you read.

Last and certainly not least, upgrading your headlight bulbs is not a free-for-all. As with audio system upgrades, enthusiasts often think they know more than the engineers who designed the factory-installed systems. Longevity, legal compliance and thermal management are key considerations when designing a lighting system. We’ve seen many examples of high-output aftermarket headlight bulbs melting reflectors and lenses. We suggest the “better solutions” approach rather than the “brute force” approach to improving forward lighting.

Headlight Technologies
A reflector assembly inside a first-generation Hyundai Genesis sedan melted because 55-watt bulbs were used instead of 35-watt units.

Up next in this series, we’ll examine aspects of lighting like lumens, candelas, lux, watts, color and temperature.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: Uncategorized

How Is the Power from My Amp Divided Between My Subwoofers?

Amp Power

We see a lot of questions like “My car audio amp can produce 800 watts; how much power does each of my subs get?” If you aren’t versed in the calculation basics of Ohm’s law, the answer might not be intuitive. Let’s dive into the math and logic that will let us calculate how the power from an amplifier is distributed through multiple speakers or subwoofers.

How Much Power Does an Amplifier Produce?

Without going off about the unimportance of power production versus amplifier quality, we should discuss what determines how much power an amplifier can produce. Most car audio amps use a switching power supply that is designed to chop up and boost the 12 to 14 volts from the battery and alternator, then regulate it to fixed DC voltages that drive the output devices in the amplifier. We refer to these as rail voltages, and they determine the maximum voltage available to the speaker terminals and, ultimately, the speakers or subwoofers.

If we use the example of an amplifier with +30- and -30-volt rails, we have a maximum theoretical voltage of 60 volts that we can apply to the speaker. Ignoring some losses through the output devices themselves, this amp could provide 900 watts into a 4-ohm load. The formula to calculate power given voltage and resistance is P = V^2/R.

Unless the amplifier uses a stiffly regulated power supply design, the rail voltages are typically a fixed multiple of the supply voltage. We’ll ignore some losses and say 30 volts is 2.08 times the supply voltage of 14.4 volts. If the supply voltage drops to 12 volts, our rail voltage would then drop to 25 volts, and we’d only have 50 volts we could use to drive a subwoofer. Our maximum theoretical power is now only 625 watts. This example highlights the importance of ensuring that the most possible voltage is delivered to your amplifier and why you should never skimp on power wiring.

How Amplifier Power Is Divided into Multiple Subwoofers

Our example so far has discussed a single 4-ohm load. What if we have two 8-ohm subwoofers wired together to the amp? How much power can it produce? The answer depends on how the subwoofers are wired. If the subwoofers are wired in parallel to get a net load impedance of 4 ohms, then the amp would produce 900 watts – the same as with a single 4-ohm load. Because both loads are identical, that 900 watts of output is shared evenly between the drivers, with 450 watts going to each.

Now, what happens if we decide to wire the subwoofers in series? An 8-ohm subwoofer wired in series with another 8-ohm subwoofer gives us a net load impedance of 16 ohms. Our amplifier can only produce 156.25 watts into a 16-ohm load. As both subwoofers have the same impedance, the power to each sub is divided evenly, with each receiving 78.125 watts. It’s very unlikely that we would want to run an amplifier at 16 ohms, even though it might be quite efficient.

The amount of power an amplifier produces depends on the maximum unclipped voltage it can produce on the speaker outputs, the impedance of the speakers connected to the amp, and how much current the amplifier can supply to the speakers. Why is current a consideration? What if we connect a 2-ohm subwoofer to our example amplifier? Theoretically, the amp should be able to provide 1,250 watts. In order for this to happen, the amplifier needs to be able to supply 25 amps to the load. That formula is I = P ÷ V, where I is current in amps, P is power in watts and V is voltage. For a well-designed, high-power amplifier, 25 amps isn’t an unreasonable amount of current.

What happens if we connect a 1-ohm load to our amp? The theoretical power jumps to 2,500 watts, and the amplifier would need to be able to supply 50 amps of current to the load. If you’ve looked at amplifier specifications where an amplifier’s power output capabilities don’t roughly double as the load impedance is divided by two, it’s likely because the amp can’t provide the required current into the lower impedances.

Amp Power
Four ARC 8 subwoofers powered by an X2-1100.5 by Speed of Sound in Memphis, Tennessee.

Why the Confusion about Amp Power Ratings?

Over the decades, we’ve been taught to think that amplifiers double their power when the load impedance is cut in half. An amp that produces 300 watts into 4 ohms should produce 600 watts into 2 ohms and 1,200 watts into a 1-ohm load. The massive “cheater” amps that were popular in the 1980s and ’90s were often rated similarly to this. However, things have changed significantly.

Let’s look at an example of a modern high-quality subwoofer amplifier like the Rockford Fosgate T500-1bdCP. This amp is rated to produce 300 watts into a 4-ohm load, 500 watts into a 2-ohm load and 500 watts into a 1-ohm load. We can tell from the 4-ohm rating that the amp likely has rail voltages of roughly plus and minus 17.5 volts. Knowing how Rockford Fosgate under-rates their products, the rails are likely running at 19 volts, and that amp would produce roughly 360-ish watts into a 4-ohm load. Nevertheless, let’s stick with the 17.5-volt rails for this discussion. Running a 2-ohm load should then produce just over 600 watts. It’s clear that current delivery into the lower impedance is the limiting factor if the amp is rated for 500 watts. Our math says the amp is limited to about 17.5 amps of current into the speaker load. That’s why the amp doesn’t produce more power into a 1-ohm load.

Amp Power
Three ARC Audio SW10 subwoofers powered by a 1,000-watt ARC 1000.2 amp. Each sub gets 333 watts of power.

Current-Limited Amplifier Design Considerations

Why would a manufacturer of high-quality audio products make a design decision to limit how much current one of their amplifiers can produce? The first consideration is heat management. We’ve tested many Rockford Fosgate amplifiers in the past few years. Their high-mass heatsink designs typically allow their amplifiers to run at maximum output continuously for at least 30 minutes if not more.

While 30 minutes doesn’t seem like a long time, for car audio amplifiers, that’s an amazing performance. We’ve seen compact amplifiers from supposedly reputable brands that overheated and shut down in less than three minutes at their maximum undistorted output. Some Brazilian amplifiers we’ve tested shut down in less than two minutes at full power. Reliability is as important as audio quality – you don’t want your music to stop playing because a poorly designed amplifier overheats.

The second reason for the limited-current design is that the output when driving a 4-ohm load is higher. In a classic design that is closer to doubling its power, the amp would only make 125 watts into 4 ohms if it made 500 watts when driving a 1-ohm load. Amp design is much like speaker design in that you have to trade one performance factor for another. As such, it’s not really a “current limited” design; it’s just optimized in a different way than the car audio industry is used to.

Amp Power
The T500-1bdCP not only sounds great, but its thermal management helps ensure reliable operation.

Guidelines for Amplifier Power Distribution

Here’s the takeaway in terms of figuring out how much power each subwoofer or speaker connected to an amp will receive. First, determine what your net load will be to the amp. Our article about “Ohms and Loads” can help you with that. Next, look at the amplifier’s published specifications to determine how much power the amp should make. If the specifications aren’t compliant with the CTA-2006-D standard, be wary of their accuracy. Finally, divide the expected power from the amp evenly among the subwoofers connected to the amp.

The above comes with a caveat: All the speakers or subwoofers must have the same impedance. We strongly recommend not mixing and matching drivers with different impedances on the same amplifier channels.

A single 4-ohm subwoofer on our T500-1bdCP would receive 300 watts. A pair of 8-ohm subs wired to a 4-ohm load would result in the amp producing 300 watts, and each driver would get 150 watts of power. If we run a single 2-ohm sub on the amp, it would get 500 watts. If we ran two 4-ohm subs wired in parallel, the amp would produce 500 watts, and each subwoofer would get 250 watts of power. A single 1-ohm sub would get 500 watts. A pair of 2-ohm subwoofers wired in parallel would get 250 watts each. Four 4-ohm subs wired in parallel would result in the amp producing 500 watts, and each sub would get 125 watts.

One last word of advice: Loading your amplifier down to lower impedances in hopes of it making more power will dramatically reduce its efficiency and likely shorten its lifespan.

Upgrade Your Vehicle with a Subwoofer System Today!

We’ll circle back to the beginning of this article to remind everyone that power production has no correlation to audio system quality. You could have a 2,500-watt amplifier, but a better-designed 1,000-watt amplifier might sound better and produce bass that is more accurate.

If you have several subwoofers and want help choosing a great-sounding amp for them, drop by a local specialty mobile enhancement retailer and find out about the solutions they have available. They can explain the options for wiring the subwoofers you have or suggest solutions that will offer amazing performance.

Lead-In image credit: Thanks to Bing from Simplicity in Sound in Milpitas, California, for providing the photo of the four Sony Mobile ES XS-W104ES subwoofers.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Car Audio, RESOURCE LIBRARY

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