Bicycle light generator
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Contents |
About
Bicycle light generators are used to power battery-less safety lights mounted on bicycles. Safety lights are important to bicycle enthusiasts alike as they provide the necessary lighting to traverse a road as well as inform auto drivers of the bikers presence at night. The generator converts the energy put into the bicycle in the form of a pedaling motion into an electric current through the friction developed by the generator’s contact with the wheel of the bicycle.
The purpose of the bicycle light generator project is to dissect and understand the design processes behind this product. Our goal is to study this product thoroughly in order to engineer a modification that will result in an improvement in its functionality.
In our preliminary observation, we have noticed that current generator powered bicycle light sets do not have a means of storing power. As a result, these generator powered bicycle lights do not operate when the bicyclist is not pedaling and could be hazardous when the stopped at a traffic light.
In an attempt to incorporate a power storing functionality, we will also be studying a hand-crank generator powered flashlight. Using the same principles as a generator powered bicycle lights, these flashlights also have a rechargeable battery pack that is able to store power; thus, allowing the user to operate a light without having to input energy at the same moment.
Use
The installation of the power generation is probably the most difficult part. The user has to first analyze the structure of the bike and choose a location to mount the headlight. Since the light mounting mechanism is not universal, a hole on the front fork is required for mounting with an additional screw. User can also purchase a set of universal mounting device for the installation of the front and rare lights. The generator should be positioned vertically and that the roller connects with the middle part of the tire. The grounding screw on generator bracket must be screwed in completely to make contact with the metal of the bicycle frame. To complete the power generator circuit, connect headlight wire and tail light wire with generator terminal by pressing down the metal connector on the generator and put wires through the metal hole, then release the connector so the metal part of wires get stuck in that hole. It is very important that the generator and the lights are properly grounded to metal parts on the bike. The tail light can be fastened to rear frame stay of bicycle. Finally, press lever on the generator downward so the roller touches the tire. Before riding the bike, be sure that all screws are tight and that the wires and generator are clear of all moving parts. To activate the front and rare lights, user would have to rotate pedals by riding the bike.
1. Choose a location to mount the headlight and rare light.
2. Position generator so that the roller connects with the middle part of the tire.
3. Ground the generator by screwing the bracket to the metal of the bicycle frame.
4. Connect headlight wire and tail light wire with generator terminal.
5. Wind generator cable to avoid getting entangled.
6. Press lever on the generator downward so the roller touches the tire.
7. Rotate the bike pedals to activate the generator.
8. Confirmation the activation of the front and rare lights.
Functions
The rotation of the bicycle tires causes the roller on the power generator to spin due to friction. Since the roller is connected to the shaft, it would transfer the rotational force to the motor. The mechanical force generates magnetic fields in the motor and creates a current that goes through the small metal connector. The metal screws coming out of both lights serve as grounding devices. The wire that connects the small metal connector and the bicycle lights would carry the current through the entire circuit and light up both lights.
Hand-Crank Generator Flashlight Components:
Part # | Part name | QTY | Function | Materials | Dimensions | Manufacturing Process | Picture |
---|---|---|---|---|---|---|---|
001 | Case | 2 |
| Plastic | 8" x 2" x 2" | Molding | |
002 | Case Screws | 4 |
| Metal | .3" x .2" x .2" | ||
003 | Grips | 2 |
| Plastic | 12" x 5" x 3" | Injection Molding | |
004 | On/Off Button | 1 |
| Rubber | .5" dia. | Stamped | 100px |
005 | Crank Handle | 1 |
| Plastic | 3" x .5" x .25" | Molding | 100px |
006 | Crank Pivot | 1 |
| Plastic | 2" dia. | Molding | |
007 | Crank Washer | 1 |
| Plastic | .75" dia. | Stamped | |
008 | Crank Pin | 1 |
| metal | .5" x .1" dia. | ||
009 | Crank Knob | 1 |
| Plastic | .25" x .25" | Molding | |
010 | Lens Cover | 1 |
| Plastic | 3" dia. | Stamped | |
011 | Lens Holder | 1 |
| Plastic | 3" dia. | Molding | |
012 | LED Housing | 1 |
| Plastic | 3" x 2" x 2" | Molding | |
013 | LED Lights | 1 |
| Plastic, Semiconductor | .1" dia. | ?? | |
014 | LED Circuit Board | 1 |
| Sillicon, Conductor | 2"x2" | Stamped | |
015 | Motor | 1 |
| Magnet, Copper wire | 2" dia. | ? | |
016 | Gears | 3 |
| Plastic | Sizes vary | Stamped | |
017 | Gear Housing | 1 |
| Metal | 3"x2" | Stamped | |
018 | Motor Circuit Board | 1 |
| Sillicon, Conductor | .25"x .25" | Stamped | |
019 | Gear Housing Screws | 4 |
| Metal | NA | NA | |
020 | Switch | 1 |
| Plastic | .25" dia. | Stamped | |
021 | Switch Housing | 1 |
| Plastic | 2"x1" | Stamped | |
022 | Recharable Batteries | 4 |
| Metal, Chemicals | 6V | NA | |
023 | Indicator LED Circuit Board | 1 |
| Sillicon,conductor | 2"x2" | Stamped | |
024 | Indicator LED | 2 |
| Diode | NA | NA |
Part # | Part name | QTY | Function | Materials | Dimensions | Manufacturing Process | Picture |
---|---|---|---|---|---|---|---|
001 | Generator Assembly | 1 |
| Metal | 4" x 2" x 3" | Multiple | |
002 | Generator Hole | 1 |
| Metal | .25" dia. | ||
003 | Generator Metal Connector | 1 |
| Metal | .1" x .1" x .1" | Stamped | |
004 | Generator Mount (Back) | 1 |
| Metal | 3" x .5" x .25" | Stamped | 100px |
005 | Generator Mount (Front) | 1 |
| Plastic | 3" x .5" x .25" | Molding | 100px |
006 | Generator Mount Hex Screw | 1 |
| Plastic | 2" dia. | Molding | |
007 | Crank Washer | 1 |
| Plastic | .75" dia. | Stamped | |
008 | Crank Pin | 1 |
| metal | .5" x .1" dia. | ||
009 | Crank Knob | 1 |
| Plastic | .25" x .25" | Molding | |
010 | Lens Cover | 1 |
| Plastic | 3" dia. | Stamped | |
011 | Lens Holder | 1 |
| Plastic | 3" dia. | Molding | |
012 | LED Housing | 1 |
| Plastic | 3" x 2" x 2" | Molding | |
013 | LED Lights | 1 |
| Plastic, Semiconductor | .1" dia. | ?? | |
014 | LED Circuit Board | 1 |
| Sillicon, Conductor | 2"x2" | Stamped | |
015 | Motor | 1 |
| Magnet, Copper wire | 2" dia. | ? | |
016 | Gears | 3 |
| Plastic | Sizes vary | Stamped | |
017 | Gear Housing | 1 |
| Metal | 3"x2" | Stamped | |
018 | Motor Circuit Board | 1 |
| Sillicon, Conductor | .25"x .25" | Stamped | |
019 | Gear Housing Screws | 4 |
| Metal | NA | NA | |
020 | Switch | 1 |
| Plastic | .25" dia. | Stamped | |
021 | Switch Housing | 1 |
| Plastic | 2"x1" | Stamped | |
022 | Recharable Batteries | 4 |
| Metal, Chemicals | 6V | NA | |
023 | Indicator LED Circuit Board | 1 |
| Sillicon,conductor | 2"x2" | Stamped | |
024 | Indicator LED | 2 |
| Diode | NA | NA |