Modification Justification And Rendered Solid Works Image Of Final Design To My Light Design

I have decided to modify my original design of my 'Slim" light design.there are going to be two main changes.

1.I have decided to not use the large solar panel because of the size of it.but instead to use 5 of the 40mm by 40mm solar panels..

2.Also the height of the base will have to become taller so the solar panels will fit on the base. I am increasing the base by 20mm so now the height of the base will be 60mm.

The solar panels will be placed on the side of the base of the light and when the light is wall mounted the solar panels will face up to the sky - this will allow maximum sunlight to the solar panels therefore I will be able to use more lights in the circuit.

Chirag

Mockup and edited new final slim light design

Week 2 Term 3 08

On friday i edited my template light evaluation and did practical for the rest of the periods.In practical i begun to make my mockup of my final light design.On tueday i completed my mockup of my final light design.I have discussed with terry about a major modification to my light .I am going to add 5 of 4 small solar panels to my final light design the will be added to the side of it to produce more light.

Week 1 Term 3 08

Yesterday we went on the computers and got given a partener and we had to place feedback on each others final design.in my feedback that was given to me by the great James Croft.today we are udatting our blog i also reposted my template light evaluationb and added some modifications to it on fri we have double prac

Template Light Evaluation 3.2

I have just completed my prototype solar light. It is working as it should. The process of this prototype solar light began On Tuesday May the 13th.

We had a brief given to us by a man named Terry Hawkins
The brief was to modify the circuit and make an aluminium box that would fit the circuit.

We were given working solar panel lights which were purchased from the warehouse for a cheap amount of money. We disassembled the solar panel light as it was in a cheap plastic container. We then removed the circuit and all components from the cheap plastic container. We did this so we could modify the circuit and add two LED’s.

After we disassembled the circuit we put all the pieces into a bag. We then began to make the aluminium box. Terry had all the templates of the box already cut to save time. The aluminium template was cut in the cam machine because it is a lot faster than manually cutting it.

Aluminium Box

We first marked lines on the aluminium template that showed were the folding points were. We then folded the aluminium template into a box shape. Each bend was made with a 90 degree angle. Then after the box was folded we made brackets for it.

The brackets were made by cutting out bits out of scrap aluminium with the guillotine. We marked the bending points in each bit of scrap aluminium then bent them into shape at a 90 degree angle.
We then marked out the points were the rivets could go through we drilled them out using a 2.5 drill bit. We had to drill the holes in specific places to prevent the rivets hitting each other in the box. Then we attached the brackets onto the box with aluminium rivets. The bottom of the box was now completed.

Then we made the top plate of the box this again was cut out with the cam machine to save time. We marked out the folding points then bent the edges at a 90 degree angle. This was followed by drilling holes and attaching the top plate to the bottom of the box. Then I screwed it on the box. The box was now completed.

Modifying The Circuit

The circuit had to be modified. We modified it by Adding two stronger and brighter LED’s (there used to be one weak LED before undergoing modification) we also changed the circuit from series to parallel. I had a bit of trouble with changing the circuit from series to parallel. I completed a full analysis of my circuit and to my dismay there was a dry joint so I fixed this problem.

We also added a new battery connector. Once my circuit was working I attached it into my Aluminium box and made sure all connections had heat shrinked tube on them to prevent short circuiting. I then attached the solar panel to the circuit. I made the LED stick out of the box and the stayed there with hot glue. The solar panel was stuck onto the box with silicon.
The light now works as it should.


This process was completed in the given time frame

Chirag =)

Template Light Evaluation 3.2

Aluminium Box I have completed my prototype solar light. It is working as it should. The process of this prototype solar light began On Tuesday May the 13th.

We had a brief given to us by a man named Terry Hawkinsthe brief was to modify a circuit and make an aluminium box that would fit the circuit.

We were given working solar panel lights which were purchased from the warehouse for a cheap amount of money. We disassembled the solar panel light as it was in a cheap plastic container. Were then removed the circuit and all components from the cheap plastic container. We did this so we could modify the circuit and add brighter LED’s.

After we disassembled the circuit we put all the pieces into a bag. We then began to make the aluminium box. Terry had all the templates of the box already cut to save time. The aluminium template was cut in the cam machine because it is a lot faster than manually cutting it.

We first marked lines on the aluminium template that showed were the bending points were. We then folded the sides that stuck out of the aluminium template at 90 degree angles. After all 4 sides were bent the aluminium template formed a box shape.
Then after the box was folded we made brackets for it. These were made by cutting out bits out of the scrap aluminium with the guillotine .We marked the bending points in the bits of scrap aluminium then bent them into shape – Bending bit of scrap aluminium at a 90 degree angle so they were ‘L’ shaped. We then marked out the points were the rivets could go through we drilled them out using a 2.5 drill bit. We had to put the holes in specific places to prevent the rivets from hitting each other when inserted in the box. Then we attached the brackets onto the box. The bottom of the box was now completed.

The next step was to create the top plate of the box this again was cut out with the cam machine to save time. We marked out the folding points then bent the edges at a 90 degree angle. Then drilled holes and attached it to the bottom of the box using screws. Modifying The Circuit The circuit had to be modified. We modified it by Adding two stronger and brighter LED’s (there used to be one weak LED before undergoing modification) We also changed the circuit from series to parallel. In the process of changing the circuit from series to parallel I had a problem. The problem was that the circuit didn’t work. I did a complete analysis of the circuit and to my dismay I discovered that my wire connection to the circuit board had broken so I had to re-solder the joint. This corrected the functionality of my circuit We also added a new battery connector. Once my circuit was working I attached it into my Aluminium box. Then I discovered another problem. The wire connection was touching the aluminium box and causing the circuit to short circuit. So I took out the circuit of the box and disconnected the wire connection and placed heat shrinkable tube and made sure all other connections had heat shrinked tube on them to prevent short circuiting. This solved my problem.
I then attached the solar panel to the circuit. I made the LED’s stick out of the box and the stayed there with hot glue. The solar panel was stuck onto the box with silicon. The light now works as it should.

This process was completed within the given time frame

Chirag =)

Week 9 Term 2

last friday i finished my circuit.allthough i had 1 problem - my circuit was not working in the aluminium box.I found out that i had forgotten to put a rubber tube thing on a connection of wires so i disconnected that connection of wires and put the rubber tube thing on then heat shrinked it.the circuit now works in the box.i then attached the solar panel to the box with silicon.yesterday i worked on solid works and uploaded images of my rendered solid works image .today im doing an engineering drawing of my design