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Designs for PCB and Enclosure

Questions

What are we trying first/what do we want?

  • use polycarbonate lens in terms of waterproofing

  • make enclosure taller or squintier

  • headlights very big, taillight shape narrower, sidelights very tiny, high mounted brake light longer

  • high mounted brake light a lot of space to work with

  • tail lights will cover brake lights and signal

  • amber colour for signal lights, brake lights are red

  • similar taillights and high mounted brake light long rectangles

  • stick on side mirrors - tiny round lights (last year)

    • less power for small lights (side mark indicator lights)

  • 10cm board with 4 leds equally spaced

  • the entire light doesn't light up - it's a beacon of light little (pin lights)

    • giant lens with little bright light in the middle

  • max thickness is 3-4mm thick for material

  • headlights are already polycarbonate casing

  • make diffusion materials different colours and lens cover is clear

  • headlights thermoformed

  • casted plastics being a good option

  • 3d printing but issues with clear

    • cant thermoform over .5cm thick

  • spread heat onto larger surface with pcb and attach the heat sink

  • natural airflow to cool down high mounted break lights??

  • generous airflow for headlights

  • for the heat sinking assume lights always on to not risk firmware bug

  • estimate cooling needed - based on power expected to consume and translate into heat. figure out the mass of material needed to transfer into for certain rise in temp of material - specific heat capacity of material
    or data sheet of heat sinks

  • size of heat sink (maybe 60x30mm finned)

  • viewing angles for the leds

    • side lights are the most important

    • wide-angle lens will disperse the lights more and make them dimmer

  • maybe 4mm thick acrylic for diffusion ???

  • how far do leds need to be spaced ???

  • can you see the light from 30m away ??? (testing this week)

    • estimate luminosity at 30m away

  • what is the minimum number of leds for 30m away and size of the enclosure ???

  • flat shape for the plastic covering instead of rounded ????

  • pretty complicated looking design

  • casted plastics but max temp is low ?

    • (***polycarbonate resin has a working temp range from -20-140C)

  • 3d print the part and cast the mold

  • resin casting - max temp the plastic can withstand is an issue

  • if lights too bright than we can start diffusing until reference light intensity is met

    • diffusion material determined after testing

  • right now determine enclosure spacing

  • control one led strip per light enclosure (multiple maybe ???)

  • can focus on aesthetic hehe

  • test leds and adrian will look into what will look the nicest


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