EVALUATION -relating to brief specs and constraints

In the brief which Dr Tony House gave us it stated that we needed to make a self powered solar powered light which would be robust against outdoor conditions eg salt water, wind and rain . The light also had to turn on at night and off during the day. It also needed to not stand out in the environment.
My light is only 250mm high and 160mm by 160mm wide which should help it from being blown over in high winds, As asked in the brief
I have made the shell of the box out of aluminium as it will not rust with the salt spray and rain and would help to keep my budget down I have made the shell of my box very strong so even if it gets blown over in high winds it will be ok.
I have used LED cluster which will mean that Dr Tony House would not need to waste time putting in new light bulbs as the LED cluster will far out last most standard light bulbs. By using a LED cluster I have gone over my budget of $30 as the LED light was $26 and the big solar panel was $36 but by using this big solar panel it means that the light will recharge the battery even on dark winter days.
I have put the LED cluster inside the box as this will save it from the wind and rain. I have made the sides out of Perspex as it is all low cost and will be ok outside and its far stronger than glass which would get broken if the light was to blow over.
My light has gone over budget a lot but because of this my light is far better than it would have been. I have also sealed it with silicon to help keep out the salt water and rain.
　
　
Michael Ballinger 11dtm US 90050

EVALUATION- changes to final design

In the brief from Dr Tony House he stated that we needed to make a solar powered light which would be kept outside in his garden. This means that it has to be robust so it can withstand the wind, rain and most of all salt spray. It has to turn on and off by itself. Dr Tony also asked for a dimmer switch and we only had a budget of $30 to work with.

At first I was thinking about making my light out of stainless steel. But this would have been far to expensive so my next option was aluminium. I decided to use aluminium for lots of reasons one of which is that aluminium is low cost and its easy to work with as it is soft and does not rust so it would meet the brief and look good for a long time.

After deciding about what material to use I came up with the idea of the design for my light and drew it in my book.My teacher gave me the idea of using 4 solar panels but this would not have worked with my idea .I could not use a halogen light as it wouldn't produce enough power to power the battery pack or light. Instead I used a 1w 6v solar panel that completely blew my budget.

I then modified the design of my light to accommodate the solar panel.I also thought of using a 6v lead acid rechargeable battery. After discussing that idea with the teacher we decided not to as it would take up to much space and cost too much and the solar panel would not recharge the battery as it need a charging voltage higher than 6v.So instead I used 4 AA rechargeable batteries in a battery holder which gave me 6v.

To drive the light I modified the circuit that I made earlier in the year by connecting the wires of the 6v circuit which already had a dimmer switch and
a LDR ect. But my idea for what light to use was debated between me and the teacher and so in the end we decided to use a about 1watt LED cluster.
The construction of the shell of the box went well as I had a plan to make it to big so that I would not have to use the cam machine.

So I ended up scribing out two nets on two different sheets of aluminium which went 100% the way I had planed. Then I used the gulateen to cut where possible. I had to sit down and use a piecing saw to cut out the other bits. To cut out the centre I drilled out lots of holes just inside the outline. Then I used a flat head screwdiver to knock out the bits between the holes
I the filed the sides nice and smooth..

Then it came time for me to make the brackets.I could have used the cam machine for this but I did not as it was giving other people hell. I just marked one out on a strip of aluminium and I centre punched the holes and drilled them out. Then I used this as a template and I made 3 more the same. Then I bent them 90° in the metal bender I drilled holes in the bottom ½ of the box and riveted them on.

Then it was time to cut out the Perspex so I measured out a strip and got someone to help me cut it using the band saw. To get a nice flat line the teacher put it on the belt sander for a bit. It did the job but I would not do it that way next time as the sanded side went all black and (shit) as it melted. Then I cut it into 4 pieces and fitted them to the inside of the box. I drilled out the holes and riveted them on but before that I had to make all the rivets that I used shorter. It took a long time but in the end it gave a far nicer finish.

Then I fitted the circuit and all other wiring and attached the light holder and fitted the top using 2.5 mm self tapping screws. Then I glued on the solar panel with super glue , which did not work. I ended up attaching it with silicone. I then left it to charge up in the sun. When I tested it everything worked the way it should have. I was ready happy with the way it has turned out as a lot of time and work had gone into making work. Next time I would add a cone to the top inside of my box to help make the light reflex more.

Problems encountered:

one of the problems i encountered was that the 6v 1w solar panel would not have power to recharge the lead acid battery which i was going to use

also the 1st circuit i tested which was out of a warehouse light i tested it using the led light and 4AA -6v batterys over heated and just did not work so i used the circuit i made earler in the year

the two nets would not fit in cam machine so had to be cut out using a piecing saw

Michael ballinger 11dtm us 90050

meterials list

tool lists

term 4 week 5 last blog

hello blog for the last time once agent i came in on Saturday and got the light 100 percent done then wot i did was i put more glue on the circuit and dilled out the holes then i used self taping screws to put the bottom plate on i all so put some silicon on to help keep the water out i all so glued the wire to the side and then i put the top on and drilled out the holes and put in the self taping screws then i glued the solar panel on then it was all done then the over time i have been the over time writing my evaluation

term 4 week 4

hello blog how are you doing today time is running out fast a lot needs to get done once again i came in on saturday 12-4pm i had to get my big circuit going 1st i had to take out the LEDs and solder to bits wire on then i put more wire on the LDR then add heatshrink on then i added on the battery holder then a put the wires for the solar panel then on tuesday i put the batteries in the holder then glued all the circuit then it was time to go on the over day at lunch time i cut out a bit of aluminium then i screwed it to the box then today i am typing this and adding pics i am all so going to come in the weekend

reflective practice

term 4 week 3

hello blog time is moving fast once again me in on Saturday i ended up getting all the acrylic on then i got the circuit as the PCB brooking was cover in hot glue so i had to take it off but when when i was taking of the glue i broke some of the parts so i had to take them off and put two new parts on witch i did then i cut a bigger opening in the box and filed down then on Tuesday i filed down the box more then i went down to jaycar and got a battery Holder then we all had to go home on Friday i would like to get the circuit all done

Michael

video blog

* what have you enjoyed about 11dtm
*what have you not enjoyed
* have you enjoyed bloging over wiriting if yes why
* how do you think you have achieued this year
*do you like your final disign
* how diffent is your design

term 4 week2

hello blog lots has been done in the last week I ended up coming in on Saturday for 2 hours I drilled the holes for the screws and put them in than we worked out what light I should uses then I had to go to jaycar and get it but we could not find the right fitting at school so it was back to jaycar then I put the hole to bolt it down and put the wire through after that it was time to go home on Tuesday I put two bits of wire on the light holder then I bolted it to my box today I am writing or should I say typing this. I have also done my calendar. On Friday I would like to rivet all the plastic on and put the top on.

term 4 week1

hello blog today i have done my calendar for the last 3 weeks i have all so edited my blog and put the blogs in the right order i have all so done my holiday blog on wensday we maybe doing practical i would like to get a lot down on friday i hope to get a lot done i would like to get all the acrylic on the sides of the box

holidays

in the holidays i did not end up doing a lot i ended up going sailing when the wind was not blowing only looked at the blog one time but i did not edit it i all so did a lot of time wasting and sleeping i all so did some work on the scooter and now gos faster i all so put some more paint on the boat

term3 week 10

hello blog i have been told not to say this.. on firday we only had one period of dtm as we had to go on a walk i ended up puting my brackets i put in most of the rivetss on tursady we had to do oragamy wich sucks but it was bettetr than paperwork today we are bloging and we may do some work on firday we only have 1/2 a day

term3 week 9

hello blog on Tuesday I drilled out the holes for my brackets and put them on I only ended up putting one on as I run out of time it was slow going one thing which did not help was the fact I had to cut down the rivets I used as that were far too long today I have done my calendar and I am writing my blog on Friday we only had 1/2 the time as in period 3 we have to go on a walk for some play people say is not that good

term3 week 8

this week not a lot got done as we had the week of as study week but i ended up comeing in after my exam i cut out three squares for my box and made one of my brackets for my boxs picers can be seen on my blog

term3 week 7

hello blog on Friday i finally cut out my 1st net it was slow going and i had to use a coping saw then i had to file the edges nice then i had to cut out the center so i had to drill lots of holes next to each over then i used a flite head screwdriver and hammer to knock out the had to move parts then i had to file the side nice then i marked out the side then on Tuesday i started cuting it out today i am witting this f-ing blog on Friday i am away sailing

term3 week 6

hello blog on Friday we had a doable practical i was working on cutting out my net for my box the net I'm working on now is for the bottom i had to slowly cut it out using a coping saw it was slow going but in the end i did it i cut it out you can see picter of this on my blog on Tuesday we got a new chak list witch i have just about done i need to do so fixing up of my blog sometime today i am witting and or typing then i will add more picter

MY MOCK UP- IN CARDBORD

THIS IS WOT MY CARDBORD MOCK UP LOOKS LIKE MY LIGHT SHOULD LOOK LIKE THIS

term3 week 5

hello blog on Friday i spend a lone time working out how i was going to make my box come to life after sometime i worked it out then we had lunch after lunch we got start back to work i had to get a big sheet of aluminium and marked out a piece to cut of then with Jamie help i cut the piece of using the big cuter then i cut the piece i cut of up more then it was pack up time this week started of slow on Tuesday i gout out my mock up and aluminium and marked out lines to cut and bend i used a pare of odd leg calipers to make the line picture can be seen on blog today i have done my calendar and i am typing up this blog then i will add some pic's

term3 week 4

hello blog last Friday i was away sick probably because i went sailing the night before on Tuesday. we had to fix up our labels today i an writing/ typing this blog wich i hate doing as we are doing practical i may cut out a net for my box one problem is the net is to big to fix on the cam machine ......... so cos of that in not going to use it




michael

term3 week 3

hello blog this last week went fast on Tuesday we had practical i was working on my mock up i have found that some parts of my box may not fix on the bed of the cam machine as their is a big top and bottom plate which fold up my box is all so going to be bigger than i would have liked it to have been today i am witting this i have all so done my calendar on Google you can see my calendar on my blog on Friday i will work on my mock up box and i may even start make it out off aluminium

MATERIAL JUSTIFICATION

I have decided to use aluminium in my final design as it will stand up to the outdoor conditions. It will not rust and it is low cost and is easy to work with. It has a nice finish I am all so going to use clear perspecs for the windows/side’s so the light can exit the box. when used with aluminium it should have a nice clean look and all my material can be cut out using the cam machine which I may or may not use. I am going to use aluminium pot rivets to hold the whole lot together I will also use silicon to seal the lot together and keep the water out.

term3 week 2

on Tuesday i made a mock up off my final design i had to do some modification to make the battery fix in the box now my box is big so then i did some modification as the box was to high now it is lower today i an bloging i may do some solidworks wich should be difficult as i dont know how to use it on firday we are doing doble practical i am going to work on my final design and my mock up

term3 week 1

hello blog this week is the 1st week back from the school holidays on Monday. I did a peer assessment i had to look at kody's final design and wirte a comment he all so gave me a comment we all so got a new check list so today i am going to do the check list and i have all so bloged as i am doing now i have all so done my calendar on firday i am going to do some practical i may make a moke up

PROTOTYPE LIGHT AT NIGHT

as you can see my prototype light is not the best at night my next light will have more light out put at night

term1 week 9

term1 week 4

term1 week 5

term1 week 6

term1 week 7

term 2 week 9

This week has been a good week good proges has be made in typing this .... and waiting / typing up my witter up about my prototype light i have all so made good proges with my check list i have had trube doing this as some stuff my not have the right name or be posted in the right place today i gave just done my calender which is going OK then i may do some solid works i need a loot of getting use to using this on firday we are doing doable practical but i don't know wot I'm going to do but i should work it out tmow

term 2 week 8

hello blog on Tuesday i was working on typing up my evaluation which was had for me because my spelling sucks but i got all the spelling fixed up so its all good so now you can read it it' all so on my blog ... today i am witting or should i say typing up my reflection for the week and so on on firday we are / and or doing practiccal i should get my light working agen as the wire may have come off the solar panel

term 2 week 7

hello last firday i got my light working so on monday i worked on typeing the evaluation i should have this up on my blog sometime soon my be today i am wirting / typeing this as i speek and type and i have updated my calendar i my up loat some pic and do my dision and so on and so on and so on and on firday i may type - wirt up my evalution and get some ncea test i did back

term 2 week 6

on Tuesday we did practical i solded on my led and the used a heat gun to make the heat shrink shrink i all so add the battery holder and two wires for the solder panel and the srcuit work's today i am wirting this as i type i am all so going to up load pic's i took over the last week or so on Friday i should have the crcuit in the box and working

POA-CITA RESEARCH

poa-cita all so knowing as Silver tussock is found all over nz it is widespread you could say poa-cita is about

30 to 70cm tall and is brown it is oftern found by the coast it has a bush like apperances

term 2 week 5

today is Tuesday we are in the com room wirting our blog's we have up date our calendar as all way's then i will be doing some research on some grass and on wensday we will be doing some practical to get me box done we are all so doing practical on firady to get the cirting going so so our light will work and light up and so on and so on

my light diagram

term 2 week 4

hello blog this week is a shout week as we are not at school on Friday so we don't get Darbie practical on trusday we did some materials research and today i am wirting my blog and i am going to put some pic's of last firday work on my blog and so on and so on

brief - dr toin house

brief

• create a self powered light
• to light up poucita in the coromandel

constraints

• weather-outdoor coromandel
• self-powered
• cost must not be more than $60

research

• meterials
• poacte
• solar panels

specifirations

• selfpowerd
• light
• poacita

research meterials-rustprof

• stainless steel
• plastic
• tiluminium
• brass
• copper

light must turn on at night and off at day

brief

we need to make and design a self powerd solar powerd light it will be keeped outdoors in the coromandel so it will need to be weater proff we willall so need to use rust proof materials it can be no biger than 50mm high we have a cost limet of $60 gave or take

term 2 week 3

on Tuesday i drilled holes in my box for the solar panel and i made some brackets for the box today i add the pic off the making off the box on Friday we are doing two peraidos
of practical i will be working on my box and folding up the brackets and so on and so on

prototype box

term 2 week 2

hello we did the work sheet for 18242 and then we pulled apart some warehouse garden lights and took out the circuit to use in the box that we folded up on Wednesday after we did a work sheep about the parts in the light we had pulled apart today/ Friday we are up dateingthe blog and next we may do more work on our box's and so on and so on

computer generated top/bottom plate

term 2 week 1

this is our 1st week back from the school holidays on Monday we got a check list so we could check wot we have and have not got on our blog today i am waiting my blog and checking the blog using the check last on firday we are doing some practical and doing some design

component layout

solidworks boat wiring diagram

MY PCB

week 11

this week i have add all the parts on my PCB and tested it and it worked their are some pictures today i am update the blog adding pic of pcb and wirting on/in the calender on firday we may do some desion work

MY PCB

this is how my pcb was looking like over 3 perios it went from not working to working in just 3 perios

week 10

we use free hand to design a 2d model of our solar light last firday we woked on our pcb bord i soldered on 3 wires and two termina blocks this firday we will be doing more solding

MY PCB

so far i have soldered on 3 wires and two terminal one terminal is for the solar panel and the other is for the battery

MY PCB

this is my PCB Bord design we had to do in the first picture we see the Bord before the the acid bath and in the over picture it has come out of the acid the tracking is under the black pen

solar light- cirruit

solar light- cirruit

solar light- cirruit

MATERIAL RESEARCH

stainless steel
stainless steel is harder than aluminiun and copper it is all so silver in colour is a iron-carbon alloy and does not stain, corrode or rust as easily as ordinary steel (it "stains less"), but it is not stain-proof. It is also called corrosion resistant steel when the alloy type and grade are not detailed, particularly in the aviation industry. There are different grades and surface finishes of stainless steel to suit the environment to which the material will be subjected in its lifetime. Common uses of stainless steel are cutlery and watch straps it is all so used in boating as parts made off stainleess steel will not rust like steel would .

aluminiun
Aluminium, or aluminum as the American’s like to call is a solf and is silver in colour, is the third most abundant element comprising about 8% of the Earth’s crust. Despite this fact, it was only discovered in 1807 by Sir Humphrey Davy, who originally called it alumium. Davy identified it in alum, but it was not until 1825 when Oersted produced the first samples of pure aluminium by heating potassium amalgam with anhydrous aluminium chloride.
It was not until the late 1880’s when processes were developed that could produce commercial quantities of aluminium.
Aluminium is a metal and can be processed in a similar manner to other metals such as steel, copper, brass or titanium. However, its properties such as light weight, corrosion resistance and conductivity, combined with sustainability have seen its’ widespread utilization and acceptance.
The future for aluminium remains bright, however, threats from alternative materials such as magnesium should not be ignored, with increasing production and reduced prices opening up areas of possibility aluminium is offen use in windos and boats can be made out off it it is offen used in boat masts as it is light weight and dose not rust .

Copper
Copper is a soft metal it has a copper like colour has played a significant part in the history of humankind, which has used the easily accessible uncompounded metal for thousands of years. Several early civilizations have early evidence of using copper copper is used in boat building as steel nails would rust and would be no good copper is soft and will not rust but it will go green in time From 1909 to 1982, the American penny was 95% copper Today, because it is such a good conductor of electricity, copper is mostly used in electrical generators and motors, for electrical wiring, and in electronic goods, such as radio and TV sets. Copper also conducts heat well, so it is used in motor vehicle radiators, air-conditioners and home heating systems.

week 8

over the Easter holidays we have been doing some research about materials and today we are updateing our blog on firday we will be doing two hours of practical on firday

solidworks-light

homework

research the materials you want to use

homework

research the types of meterials you want to use

boat wiring diagram

pcb art work

My prototype light / evaluation

My prototype light - Michael 11dtm

For our prototype light we got a box witch was cut out on the cam machine. First I had to clean up the edges then I had to scribe lines on it to fold along. Once I had done that, I used the metal bender the bend up the sides of the box. One problem I came across was I had bended 2 opposite sides; I could only bend the other sides about 50°. So I had to bend it up to 90° by hand. I had to mark out two holes so the wire for the solar panel could go through. One thing I did was centre punched where I going to drill the hole. I decided to use a 5mm drill not a 3mm drill as the teacher said, so I ended up having a 5mm hole and then a 3mm hole next to it on top of the box but it did not matter because the solar paler went over top and covered it up if anything it made it better when It came time to put the solar paler on. I also bent the box before I marked out and drilled the holes. The next step was I had to make up four brackets for the corners of the box. First, I had to get bit of scrap aluminium and scribe out a row 20mm wide then scribe 40mm long and then divided them in half. Then I had to mark two holes on each side of the bracket. Then on the other side, I had to make two more holes which where out of line with the previously marked holes so that when I put in the rivets, they wont stick into each other. Then I used the centre punch to punch where the holes are going to be. Then I used a 3.3mm dill bit to dill the holes and then I used the guillotine to cut them in to 4 bits then I used the metal bender to bend the bracket. Then I placed the brackets on the corners of the box and used a cordless drill to drill the holes in the box for the rivets to go through. Then I used the rivet gun to put the rivets on then I did the same thing to do the other 3 brackets. I used a 3.3mm drill bit for the rivet. The rivets where 3.2 mm then I pulled apart my warehouse light and took the circuit out and I modified the circuit. I had to get a different circuit because the one in the light that I pulled apart was covered in hot glue thanks china. I got given another circuit to de solider. I had to de solder the LED and the wires. Once I had done that, I had to add two more LED in parallel. I also had to add a new battery holder but used the same battery as it worked ok the hardest part was soldiering on the solar panel. When I went to put the panel on the wire kept on breaking off but in the end I hot glued it on then I put silicon sealant around the panel to seal it up then I screwed on the bottom of the box on I used 2.5 mm self tapping screws to attach the two plates and it finally it was all working good. I think that my prototype light was a bit of a disaster because I don’t like the way the box turned out. The edges did not all match up that good but I was happy with the way the circuit turned out. Next time I would spend more time on the box and line up the holes better and put the bracket on nicer but over all it was a good out come and so on and so on.