Multimedia

Final Design

CAD Version of Final Design

3D Printed and Assembled Final Design

CAD Exploded View of Final Design

Final Assembly.mov

CAD Demonstration of Final Design

IMG_4760.MOV

Video Demonstration of Final Design

Hardware Testing

My Movie 3.mov

Drop Test Videos for Adhesion Strength and Durability Test

Order: 3ft drop - right side, left side, top, back

6ft drop - left side, top, back

Water and Dust Proof Testing for IP55

Prototype 3

The third prototype of the bike helmet task light was developed and 3D printed using PLA. With the rail system and rotation mechanism finalized, incorporating the internal lighting components into the light housing was the focus of this prototype.

Internal Components from NITECORE Tube V2.0 Light

Isometric View of Prototype 3

Exploded View of Prototype 3

Isometric Views of 3D Printed Prototype 3 with Internal Lighting Components

Side Profile of 3D Printed Prototype 3 with Internal Lighting Components

Front View of 3D Printed Prototype 3 with Internal Lighting Components

Prototype 2

The second prototype of the bike helmet task light was developed and 3D printed using PLA. The female rail was re-designed to incorporate a screw insert to prevent tapping the female rail directly. At this stage of the project, the rail system and rotation mechanism were finalized.

Side Profile of Prototype 2 Highlighting the Newly Incorporated Screw Insert

The Re-designed Female Rail

Female Rail with Screw Insert and Spring Plunger

Female Rail and Light Housing, Constrained with a Hex Screw and Washer

3D Printed Rail System (Finalized)

IMG_1308.MOV

Male and Female Rail System with Magnet Locking Mechanism

IMG_1309.MOV

Rotation Mechanism with Spring Plunger

Prototype 1

The first prototype of the bike helmet task light was developed and 3D printed using PLA. The rail system was reduced in size, the spring plunger rotation mechanism was incorporated, and a screw was used to constrain the light housing onto the female rail. The light was undeveloped and served as a general representation of the final product.

Side Profile of Prototype 1

Exploded View of Prototype 1

3D Prints of the Light Housing, Female Rail, and Male Rail (left to right)

Prototype1_Hardware.mp4

CAD Demonstration of Prototype 1

IMG_4348.MOV

Hardware Demonstration of Spring Plunger Rotation Mechanism

Incorporating Rail System and Rotation

Ideas for incorporating a rail system and rotation mechanism together began to take place. The magnet locations were shifted to have the magnet faces parallel to the rail system sliding direction, as opposed to having the faces normal to the sliding direction. Side wall supports were brainstormed to prevent the pin/pivot from experiencing all the load as the light housing was attached/detached from the permanently-mounted male rail.

Exploded View of Design Concept

Rail System with Location of Magnets

Dynamic Movement.mp4

CAD Demonstration of Design Concept

Rotation Concept

With a rail system mounting mechanism established, rotation for the light housing was desired to give the user more freedom with respect to the orientation of the light as a permanent mount would be utilized.

The use of a spring plunger as a mechanical detent was researched and would later be incorporated into the Final Design

Early Concept for Implementing Rotation

Rail System Concept

After risk reduction testing proved that a hook-and-loop mounting mechanism was unreliable, a rail system concept was proposed where a permanent mount would remain on a bike helmet while allowing the light housing to be removeable. A magnetic locking mechanism was also proposed to fasten the rail system together to prevent the light housing from slipping off.

Initial Rail System with Magnetic Locking Mechanism

Exploded View of Assembly

Initial Design Concept and Application

Assembly with a Form Fitting Material to Compensate for Helmet Curvature

Initial Design Proposal

A hook-and-loop fastener was tested to determine its reliability as a mounting mechanism. After a risk reduction impact test, results were unsatisfactory as the LED keychain light was dismounted upon impact.

Generic LED Keychain Light

LED Keychain Light Mounted Using a Hook-and-Loop Fastener

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