Lens design of LED searchlight of high brightness and distant spot

The study related in this paper is the design of a ship-mounted LED of high brightness and distant spot. The freeform lens design obeying the edge ray principle and Snell's law is presented first. Then, to fit the illumination requirement of the searchlight, we designed a freeform lens to collimate all the light rays coming from the LED. However, theoretical analysis proves that there is a critical angle for incident rays beyond which the rays cannot be collimated, and 55% is the light-efficiency limit for polymethyl methacrylate freeform lens. We then designed a combination of a freeform lens-coupled parabolic reflector that improved light efficiency to 70%. In this paper, the design of the freeform lens-coupled parabolic reflector is given in detail. In addition, tolerance analysis and the effect of manufacturing defect are presented.