Bicycle light generator

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|-
|-
-
|011 || Output Spur Gear || 1 ||
+
|011 || Lens Holder || 1 ||
-
* Drive shaft
+
* Screw cap that attaches lens cap to case
-
|| Plastic || 1" x 1" || Injection Molding ||[[Image:output_spur_gear_(7).jpg|100px]]
+
|| Plastic || 3" dia. || Molding ||[[Image:24441_Flashlight_Part_011.jpg|100px]]
|-
|-
-
|012 || Light Bulb Reflector || 1 ||
+
|012 || LED Housing || 1 ||
-
* Increases intensity of light
+
* Protects LED
-
|| Plastic+Aluminum || .5" x .5" x 1" || Injection Molding and Sheet Foil||[[Image:light_bulb_(7).jpg|100px]]
+
* Concentrates light into a beam
 +
|| Plastic || 3" x 2" x 2" || Molding||[[Image:24441_Flashlight_Part_012.jpg|100px]]
|-
|-
-
|013 || Delay Trigger Housing || 1 ||
+
|013 || LED Lights || 1 ||
-
* Houses the shredding cutoff time-delay
+
* Diodes that emit light
-
|| Plastic || 3" x 1" x 1" || Injection Molding ||[[Image:safety_housing_(7).jpg|100px]]
+
|| Plastic, Semiconductor || .1" dia. || ?? ||[[Image:24441_Flashlight_Part_013.jpg|100px]]
|-
|-
-
|014 || Cutoff Switch Time-Delay Trigger  || 1 ||
+
|014 || LED Circuit Board || 1 ||
-
* Triggers cutoff switch time-delay
+
* Support and connect wires to light
-
|| Plastic || 1" x 1" x .5" || Injection Molding ||[[Image:cutoff_switch_time-delay_trigger_(7).jpg|100px]]
+
|| Sillicon, Conductor || 2"x2" || Stamped ||[[Image:24441_Flashlight_Part_014.jpg|100px]]
|-
|-
-
|015 || Spring for Child Safety Switch || 1 ||
+
|015 || Motor || 1 ||
-
* Hold the safety switch in position
+
* Transform the rotational energy from crank into current
-
|| Spring Steel || 1/8" x .5" || Winding ||[[Image:spring_(7).jpg|100px]]
+
|| Magnet, Copper wire || 2" dia. || ? ||[[Image:24441_Flashlight_Part_015.jpg|100px]]
|-
|-
-
|016 || Bow-Tie Washer || 1 ||
+
|016 || Gears || 3 ||
-
* Attaches auotmatic safety switch to the base cover
+
* Changes the speed and torgue input of the crank and spins the motor
-
|| Plastic || 1" x 1" x 1/8" || Injection Molding ||[[Image:bowtie_(7).jpg|100px]]
+
|| Plastic || Sizes vary || Stamped ||[[Image:24441_Flashlight_Part_016.jpg|100px]]
|-
|-
-
|017 || Main Shaft Base Plate   || 1 ||
+
|017 || Gear Housing   || 1 ||
-
* Hold axes aligned
+
* Attaches gears and motor to be attached to the case
-
|| Plastic || 3" x 3" x 1/4" || Injection Molding ||[[Image:main_shaft_base_plate_(7).jpg|100px]]
+
|| Metal || 3"x2" || Stamped ||[[Image:24441_Flashlight_Part_017.jpg|100px]]
|-
|-
-
|018 || Cover Plate for Shaft Alignment || 1 ||
+
|018 || Motor Circuit Board || 1 ||
-
* Hold axes aligned
+
* Allows current to travel from motor
-
|| Plastic || 2" x 2" x 1/4" || Injection Molding ||[[Image:Plastic_top_cover_(7).jpg|100px]]
+
* Attaches motor to switch and battery through wires
 +
|| Sillicon, Conductor || .25"x .25" || Stamped ||[[Image:24441_Flashlight_Part_018.jpg|100px]]
|-
|-
-
|019 || Gear Train Housing Base Plate || 1 ||
+
|019 || Gear Housing Screws || 4 ||
-
* Holds gears
+
* Fixes gear housing to case
-
* Holds axes aligned
+
|| Metal || NA || NA ||
-
|| Metal || 4" x 2" x 1/4" || Stamped ||[[Image:gear_base_plate_(7).jpg|100px]]
+
|-
|-
-
|020 || Gear Train Housing Top Plate || 1 ||
+
|020 || Switch || 1 ||
-
* Holds gears
+
* Toggle button that turns the LEDs on and off
-
* Holds axes aligned
+
|| Plastic || .25" dia. || Stamped ||[[Image:24441_Flashlight_Part_020.jpg|100px]]
-
|| Metal || 3" x 1" x 1/4" || Stamped ||[[Image:gear_top_plate_(7).jpg|100px]]
+
|-
|-
-
|021 || Attachment Aligner for Motor Base Plate || 1 ||
+
|021 || Switch Housing || 1 ||
-
* Holds motor to gear train housing top plate
+
* Protects switch and aligns it with on/off button
-
|| Plastic || 1" x 1" x 1/4" || Injection Molding ||[[Image:motor_top_plastic_cover_(7).jpg|100px]]
+
* Allows switch to be attached to gear housing
 +
|| Plastic || 2"x1" || Stamped ||[[Image:24441_Flashlight_Part_020.jpg|100px]]
|-
|-
-
|022 || Screws  || 31 ||
+
|022 || Recharable Batteries || 4 ||
-
* Fastening
+
* Stores power from motor and releases when needed
-
|| Steel || #10-20 || Machined||[[Image:basket_(7).jpg|100px]] In the background
+
|| Metal, Chemicals || 6V || NA ||[[Image:24441_Flashlight_Part_022.jpg|100px]] In the background
|-
|-
-
|023 || Helical Blade || 104 ||
+
|023 || Indicator LED Circuit Board || 1 ||
-
* Cut paper in diamond shape
+
* Connects indicator LEDs to motor thorugh wires and provides base for LEDs
-
* Feeds paper
+
|| Sillicon || 2"x2" || Stamped ||[[Image:24441_Flashlight_Part_023.jpg|100px]]
-
|| Steel || .5" x 1\32" || Stamped ||[[Image:Helical_blade_cutters_(7).jpg|100px]]
+
|-
|-
-
|024 || Flat Blade || 8 ||
+
|024 || Indicator LED || 2 ||
-
* Feeds paper
+
* Tells user whether batteries are fully charged or are charging
-
|| Steel || .5" x 1\32" || Stamped ||[[Image:flat_blade_cutters_(7).jpg|100px]]
+
|| Steel || .5" x 1\32" || Stamped ||[[Image:24441_Flashlight_Part_024.jpg|100px]]
|-
|-
-
|025 || Paper Aligners  || 54 ||
 
-
* Ensures proper feeding of paper
 
-
|| Plastic || 1/2" x 1/4" x 1" || Injection Molding ||[[Image:white_aligner_(7).jpg|100px]]
 
-
 
-
|-
 
-
|026 || "Paper Aligner" Aligning Rod  || 2 ||
 
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* Aligns aligners
 
-
|| Metal || 1\4" x 8" || Extrusion ||[[Image:cutting_assembly2_(7).jpg|100px]] Gold rod
 
-
 
-
|-
 
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|027 || Long Main Shaft  || 1 ||
 
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* Driven by gear train
 
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* Turns blades
 
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* Aligns blades
 
-
|| Steel || 10" x 1/4" || Machined||[[Image:cutting_assembly2_(7).jpg|100px]] Center rod
 
-
 
-
|-
 
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|028 || Short Main Shaft || 1 ||
 
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* Driven by gear train
 
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* Turns blades
 
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* Aligns blades
 
-
|| Steel || 9" x 1/4" || Machined||[[Image:cutting_assembly_(7).jpg|100px]] Center rod
 
-
 
-
|-
 
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|029 || Basket || 1 ||
 
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* Collect shredded waste
 
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* Houses tab
 
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* Shredder assembly rests on top of basket
 
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* Keeps shredder assembly aligned
 
-
|| Steel || 12" x 12" x 5" || Stamp ||[[Image:basket_(7).jpg|100px]]
 
-
 
-
|-
 
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|030 || Tab  || 1 ||
 
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* Press safety switch
 
-
|| Steel || 1/2" x 1/2" x 1/2" || Stamped ||[[Image:basket_(7).jpg|100px]] On the basket
 
|-}
|-}

Revision as of 00:33, 1 February 2007

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.


Hand-Crank Generator Flashlight Components:

Part # Part name QTY Function Materials Dimensions Manufacturing Process Picture
001 Case 2
  • Protect working innerds from user and also provides a way for the user to hold
  • Aesthetics
  • Houses the on/off switch
  • Houses crank for powering the motor
Plastic 8" x 2" x 2" Molding
002 Case Screws 4
  • Securely fastens two sides of the case
Metal .3" x .2" x .2"
003 Grips 2
  • Provide ergonomic support to the user
  • Hides case screws from being accessed
Plastic 12" x 5" x 3" Injection Molding
004 On/Off Button 1
  • Guides paper
  • Protects user
Rubber .5" dia. Stamped 100px
005 Crank Handle 1
  • Creates moment arm allowing an easier motion to power motor
Plastic 3" x .5" x .25" Molding 100px
006 Crank Pivot 1
  • Allows the crank arm to be rotated circularly
Plastic 2" dia. Molding
007 Crank Washer 1
  • Attaches crank assembly to case at a fix point while still allowing rotational motion
Plastic .75" dia. Stamped
008 Crank Pin 1
  • Keeps crank pivot attached to crank handle
metal .5" x .1" dia.
009 Crank Knob 1
  • Provid user with a place to hold crank
  • Serves as a pin to keep crank housed inside case when not in use
Plastic .25" x .25" Molding
010 Lens Cover 1
  • Protects Led Housing
Plastic 3" dia. Stamped
011 Lens Holder 1
  • Screw cap that attaches lens cap to case
Plastic 3" dia. Molding
012 LED Housing 1
  • Protects LED
  • Concentrates light into a beam
Plastic 3" x 2" x 2" Molding
013 LED Lights 1
  • Diodes that emit light
Plastic, Semiconductor .1" dia.  ??
014 LED Circuit Board 1
  • Support and connect wires to light
Sillicon, Conductor 2"x2" Stamped
015 Motor 1
  • Transform the rotational energy from crank into current
Magnet, Copper wire 2" dia.  ? Image:24441 Flashlight Part 015.jpg
016 Gears 3
  • Changes the speed and torgue input of the crank and spins the motor
Plastic Sizes vary Stamped
017 Gear Housing 1
  • Attaches gears and motor to be attached to the case
Metal 3"x2" Stamped Image:24441 Flashlight Part 017.jpg
018 Motor Circuit Board 1
  • Allows current to travel from motor
  • Attaches motor to switch and battery through wires
Sillicon, Conductor .25"x .25" Stamped
019 Gear Housing Screws 4
  • Fixes gear housing to case
Metal NA NA
020 Switch 1
  • Toggle button that turns the LEDs on and off
Plastic .25" dia. Stamped
021 Switch Housing 1
  • Protects switch and aligns it with on/off button
  • Allows switch to be attached to gear housing
Plastic 2"x1" Stamped
022 Recharable Batteries 4
  • Stores power from motor and releases when needed
Metal, Chemicals 6V NA In the background
023 Indicator LED Circuit Board 1
  • Connects indicator LEDs to motor thorugh wires and provides base for LEDs
Sillicon 2"x2" Stamped
024 Indicator LED 2
  • Tells user whether batteries are fully charged or are charging
Steel .5" x 1\32" Stamped
Retrieved from "https://wiki.ece.cmu.edu/ddl/index.php/Bicycle_light_generator"
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