Bicycle light generator

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Revision as of 17:50, 11 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.

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:

Generator Bicycle Light Set Compenents:

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	Pushes toggle switch on and off	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.	?
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
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
023	Indicator LED Circuit Board	1	Connects indicator LEDs to motor thorugh wires and provides base for LEDs	Sillicon,conductor	2"x2"	Stamped
024	Indicator LED	2	Tells user whether batteries are fully charged or are charging	Diode	NA	NA

Part #	Part name	QTY	Function	Materials	Dimensions	Manufacturing Process	Picture
001	Generator Assembly	1	Convert the rotational energy from biker into an electrical current	Metal	4" x 2" x 3"	Multiple
002	Generator Hole	1	Serves as a place for generator to be connected to the generator mount	Metal	.25" dia.
003	Generator Metal Connector	1	Conducts electricty from spring inside generator Works with spring for easy installation of wire	Metal	.1" x .1" x .1"	Stamped
004	Generator Mount (Back)	1	Allows generator to be attached to bicycle	Metal	3" x .5" x .25"	Stamped	100px
005	Generator Mount (Front)	1	Allows generator to be attached to bicycle	Plastic	3" x .5" x .25"	Molding	100px
006	Generator Mount Hex Screw	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.	?
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
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
023	Indicator LED Circuit Board	1	Connects indicator LEDs to motor thorugh wires and provides base for LEDs	Sillicon,conductor	2"x2"	Stamped
024	Indicator LED	2	Tells user whether batteries are fully charged or are charging	Diode	NA	NA