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Light and Motion produces high-quality personal lights for a variety of outdoor activities including biking, climbing, and diving. The objective of our project was to design and manufacture a mounting mechanism for Light and Motion’s smaller lights. This mount had to increase number of locations a user could attach the light and consequently, increase the number of applications it could be used for. Based on the success of our project, Light and Motion expressed intent to make this interface standard for their products as an attempt to support a widened range of activities. Pictured at right is Light and Motion's “Solite” model with head lamp and battery pack. This was one of two primary devices targeted by our designs, along with the Urban model.
ABSTRACT
Goal:
• Design and manufacture an intermediate attach & release mechanism that can be used to mount light heads onto various surfaces including helmets, heads, clothing and handlebars. If the project is successful, this interface will become the standard interface designed into all Light & Motion products to support a wide range of activities.
Main constraints:
• Two main parts to take into account: light head (1) and the battery case (2).
• The designed interface can accommodate both parts, or two separate interfaces can be designed for each part.
• Project budget = $460
MOTIVATION
CONCEPT GENERATION & SELECTION
4. Vibration
Minimal vibration during use
Light pattern should remain stable
5. Strength
-Front Light:
Can withstand harsh environments and repeated exposure to rain & mud
Doesn’t break off after repeated use
Have safety factor and should pop-off / break-off at the point of impact (i.e. hitting a tree branch)
The design should be able to support devices between ~ 30 – 150 grams
6. Aesthetics and ID
Should not have protruding pieces that will affect the aesthetics as well as safety
Should look relatively smooth and aesthetically pleasing
PROJECT PLAN & FUNCTIONAL SPECIFICATIONS
DESIGN DETAILS & RESULTS The range of motion testing requirements were fulfilled for both the headlamp and battery pack. The final design (pictured at right with marks to gauge displacement) was well within our desired goal for low-profile measurements. With a short time period to allow testers to acquaint themselves with the design, the average time for assembly of the light was 3.3 seconds and disassembly took an average of 1.1 seconds. These tests show that the design fulfilled our goal of ease of use. Since the mount is universal for both the front and back devices, the user only has one system to learn.
ACKNOWLEDGEMENTS
We would like to thank the entire ME 113 teaching staff, our coach John Howard, our teaching assistant Ramanam Sampath, our project sponsor Light and Motion (Chris McCaslin), Product Realization Laboratory teaching assistants, and our fellow peers.
Team: Bora Baydere, Chris TomaseEa, Esther Vigil, Patrick McCullough, Roberto Vargas Coach: John Howard – TA: Ramanan Sampath – Project Liason: Chris McCaslin
Light & MoFon
Our design aims to be compatible with attachment to surfaces ranging from bicycles and helmets to head straps and kayak decks. The end goals for our product included creating an interface that provided reliable attachment and release capabilities along with a useful range of motion for the attached devices. Other considerations were to keep the mount lightweight, with a low part count, and compatible with a certain range of Light and Motion products. These included their “Solite” and “Urban” models, along with the battery cases associated. Our design meets all of these goals in a succinct and appealing package.
Brainstorming and Ideation: At the outset of the project, we generated a number of different concepts to demonstrate different possible solutions. Pictured directly at right are a concept demonstrating motion along two axes (near right) and a pin attachment mechanism (far right). Below are a button-release concept (bottom left) and a magnet-led idea (bottom right).
2. Low Profile
-Front Light:
Distance between the base of the mount and the base of the light < 0.75’’
Different shapes should be taken into account
Should not interfere with other objects (helmet, handlebar etc.)
-Battery Pack:
Should be as close to the neck as possible (for balance)
3. Ease of Use
-Front Light:
Can be easily attached and taken off without eye contact by the user
Can be attached to multiple locations on the helmet, as well as the handlebar (attachment for clothing is preferred but optional)
-Battery Pack:
Can be easily attached and taken off without eye contact by the user
Safely locks in place after attachment
Comparing different prototypes:
Refining the final design:
Light head BaIery pack
~50 g ~ 100 g ~ 200 g ~ 500 g
Weight Range
The mounting solution we have developed successfully meets the baseline design requirements for our project. The mounting interface provides the required degrees of motion for both a head light and a battery pack or back light. The simple and inconspicuous design is effectively low profile and causes little to no interference with the mounting surface. First time users demonstrated that our system is also easy to learn and can be used to rapidly attach and remove a device. Our testing results indicate that the design can withstand repeated use over harsh terrain, minimizing vibrations for better usability.
Looking forward, we can see a number of improvements being made upon the concept we have developed. One of these is the addition of a ratcheting surface (1) onto the inside of the ring, as pictured below. This ratchet could interface at a depth specific to the head light mount to provide more controlled motion along the yaw axis. This feature was impossible for us to replicate using our manufacturing methods because the FDM resolution precluded such small details. Our second recommendation is the use of a material like polycarbonate to manufacture the final design (2) , most likely in an injection molding process. Other recommendations include user testing different tab designs to improve ergonomy (3) and experimenting with different O-rings (4) to explore the elastic strength needed to close the mechanism.
Both the light and battery packed moved a negligible amount during both our standard riding and bike drop tests. (bike drop is pictured to the right). We only load tested our final design, because we were constantly working on the fit in order to make it as tight as possible. In a test measuring pure tensile loading, the insert popped out of the mount at an average of 5.7 kg over multiple tests.
We used a few different tools to facilitate our concept selection. These included spider charts and House of Quality tables to gauge our completion of goals and compare the strengths of our designs. In the end, our final design proved superior on a number of different metrics. Some of the key improvements made on previous iterations included:
• The flush surface created by the components when interfaced created the lowest profile
• The tab opening mechanism redirected disassembly forces to allow for greater strength and reduced flexing in the mount
• The simple circular geometry aesthetically outstripped more complex mount geometries while preserving necessary motion range
• This mount proved easy to use and provided a unified solution for both the light and battery pack or back light
CONCLUSIONS & FUTURE WORK
A progression of concepts depicting the refinement of features. These include divots to accommodate the battery pack and the introduction of the split ring, from our first circular pop-in mount towards our final design at the far right.
1. Range of Motion
-Front Light:
at least +90 degrees pitch
at least ±60 degrees yaw
light should stay in place during normal use
roll should be minimized and should not affect the beam pattern
-Battery Pack:
no rotation during normal use
should be tightly locked in place
some rotation when forced by the user is fine (±10 degrees)
Functional Specifications
Project Plan During the quarter, our team had a weekly coaching sessions with John Howard and
Ramanan Sampath on Tuesdays at 6:00pm in Peterson. We also had three meetings with our liaison Chris McCaslin in order to keep him aware of our progress and get his input on our designs. Our team met throughout the week in order to divide tasks and continue the project. The Gantt chart in the report gives an overview of our progress during the quarter.
In order to complete this project, our team had several resources readily available. We were supplied with a $460 budget from Light and Motion for design and manufacturing. Upon visiting their office in Monterrey, we were provided with all of their previous prototypes from this project along with other materials and were able to talk with the main engineer who had briefly worked on this task. We used Room 36 almost exclusively for the manufacturing of our prototypes, since all of our designs have been printed using the FDM machine.
Research into existing mounting mechanisms yielded a large number of possible attachment mechanisms such as straps, adhesives, bolted pieces, and slot mounts, among others. Our work seeks to move beyond existing mounts to provide all the functionality of strength, motion, and durability required, but in a compact and aesthetically pleasing package particularly catering to the light and sleek designs of Light and Motion’s products. Its simple geometry, straightforward attachment and removal, and reduced profile make our mount interface an engaging and practical solution.
Light & Mo*on
Team: Bora Alp Baydere -‐ Chris Tomase3a -‐ Esther Vigil -‐ Roberto Vargas -‐ Patrick McCullough Coach: Ramanan Sampath Project Liason: Chris McCaslin
Goal: • Design and manufacture an intermediate
a3ach & release mechanism that can be used to mount light heads onto various surfaces including helmets, heads, clothing and handlebars. If the project is successful, this interface will become the standard interface designed into all Light & MoKon products to support a wide range of acKviKes.
Main constraints: • Two main parts to take into account:
light head (1) and the ba3ery case (2).
• The designed interface can accommodate both parts, or two separate interfaces can be designed for each part.
• The design should be able to support devices between ~ 30 – 150 grams, and withstand considerable wear & tear due to harsh environments.
Light head Ba;ery case
1. Range of mo*on
2. Low Profile 3. Ease of use 4. Vibra*on 5. Strength 6. ID
Pop & Twist Swing
Circle Latch Pin
Square Back Modified Back
Chosen Design: Lifesaver (Pop-‐in)
Pop-‐in Version 2 Pop-‐in Lever Bu;on
Pop-‐in 3Cut Pop-‐in 4Cut
Pop-‐in (Push Tab) Pop-‐in (Shark Fin)
FINAL DESIGN: Shark Fin
• Engineer for easier injecKon molding • Integrate ratchets into the ring • Fine-‐tune O-‐ring dimensions • Account for material differences
between ABS and manufacturing material
• InvesKgate different use scenarios
