manufacturing lab report

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Lens glass:

Figure?

Function

The optics to distribute the light in the desired pattern are designed into the reflector itself, rather

than into the lens.

Making process

PC (polycarbonate) is used in headlamp lenses because it will not crack as easily as PMMA when

hit by a stone while driving .it still remains sensitive to abrasion from sand and dust so it must be coated

with a silicone hardcoat . FMVSS 108 requires that UV induce haze of headlamp material must be less

than 30% , therefore it may be necessary to coat the headlamp lens if an acceptable UV inhibitor ,often

the hardcoat will have an UV inhibitor capability.

The lens was made by molding process , it required the desired shape mold. Then the PC was

poured into the mold and left to solidify . When it was cool enough, the mold was removed . once

completely cooled , trimmed the excess to desired size.

History

Depending on the development tools and techniques in use, the reflector may be engineered from

the start as a bespoke shape, or it may start as a parabola standing in for the size and shape of the

completed package. In the latter case, the entire surface area is modified so as to produce individual

segments of specifically calculated, complex contours. The shape of each segment is designed such that

their cumulative effect produces the required light distribution pattern.

http://en.wikipedia.org/wiki/Parabola




Reflector.

Figure ?

Function.

Reflector act as a mirror to collect optimal light produced in the head lamp and reflect it forward

towards the road.

History.

Starting in the 1980s, headlamp reflectors began to evolve beyond the simple stamped

steel parabola. The 1983Austin Maestro was the first vehicle equipped with Lucas-

Carello's homofocal reflectors, which comprised parabolic sections of different focal length to improve

the efficiency of light collection and distribution. CAD technology allowed the development of reflector

headlamps with nonparabolic, complex-shape reflectors. First commercialised by Valeo under their Cibié

brand, these headlamps would revolutionise automobile design. ( Spencer, Charles (February 1984).

"Headlamp Developments With Dmc Reflectors Including Homofocal Arrangements)

Making process.

The reflector was made from thermosetting plastics material, which is injection moulded into the

required shape of the reflector. The product was shaped like a rectangular bowl. Then, the reflector was

subsequently painted for the purpose of imparting the necessary reflectance characteristics, before final

aluminising under vacuum that produced a mirror finishing on the inner surface of the reflector.

(Headlamp Optical Systems Illustrated, Explained & Compared, 2012 )


http://en.wikipedia.org/wiki/Austin_Maestro

http://en.wikipedia.org/wiki/CAD

http://en.wikipedia.org/wiki/Valeo

http://www.webcitation.org/5vLUd90yH



http://en.wikipedia.org/wiki/Valeo

http://en.wikipedia.org/wiki/CAD

http://en.wikipedia.org/wiki/Austin_Maestro




Frame.

Figure ?

Function.

The frame was used to hold the attached reflector and lens glass. Besides, without frame, the

headlamp can’t be mounted on the motorcycle. The framed have holes for screw and nut.

Making process.

It was made by metal in a molding process. Some other product was coated with chromium so it

have more attractive finishing. The frame in this project was coated with a black paint for the

finishing.



BULB:

Figure???

A halogen lamp is a type of incandescent lamp. The conventional incandescent lamp contains

a tungsten filament sealed within a glass envelope that is either evacuated or filled with an inert gas or a

mixture of these gases nitrogen, and argon . When electrical power is applied to the filament, it

becomes hot enough to become in can the filament glows and emits light. During operation, the

tungsten evaporating from the hot filament condenses on the cooler inside bulb wall, causing the bulb

to blacken. This blackening process continuously reduces the light out-put over the life of the lamp.

A halogen lamp comes with a few modifications to eliminate this blackening problem. The bulb, made offused quartz instead of soda lime glass, is filled with the same inert gases as incandescent lamps mixed

with small amounts of a halogen gas .The halogen chemically reacts with the tungsten deposit to

produce tungsten halides. When the tungsten halide reaches the filament, the intense heat of the

filament causes the halide to break down, releasing tungsten back to the filament. This process—known

as the tungsten-halogen cycle—maintains a constant light output over the life of the lamp.

http://www.madehow.com/knowledge/Tungsten.html

http://www.madehow.com/knowledge/Nitrogen.html

http://www.madehow.com/knowledge/Incandescent_light_bulb.html

http://www.madehow.com/knowledge/Incandescent_light_bulb.html

http://www.madehow.com/knowledge/Nitrogen.html

http://www.madehow.com/knowledge/Tungsten.html



Raw material

Depending on the type of halogen lamp, the bulb material is either quartz (fused silica) or

aluminosilicate glass. Quartz glass has the appropriate temperature resistance for the tungsten-halogen

cycle, which produces bulb temperatures of up to 900°C. For lamps of low wattage up to about 120

watts, aluminosilicate glass can be used.

Tungsten is used for the incandescent filament. The tungsten is received in the shape of wire that is

fabricated using a doping (adding tiny amounts of other materials) and heat treatment process.

Gases used during manufacture include argon, nitrogen, krypton, xenon, bromine, hydrogen, oxygen,

and natural or propane gas.

The manufacturing process

Some lamp components are made at different locations and shipped to the factory where the final

assembly takes place. The process for single-end quartz halogen lamps will be discussed.

Making the coil

Since a thin, straight wire has poor emission characteristics and it is difficult to fit into the lamp

bulb, the wire is wound into the shape of a coil using automated machines that resemble high

speed bobbins. To make a round-core filament is spirally laid adjacent to the next one on a

cylindrical rod. A rectangular rod is used for a flat-core filament. For a double filament, the wire

is first wound into a very fine primary coil, and this is then wound once more around a second,

thicker core. A large amount of wire can thus fit into a very small space.

http://www.madehow.com/knowledge/Halogen_lamp.html

http://www.madehow.com/knowledge/Halogen_lamp.html



A halogen bulb is made of fused quartz and filled with the same inert gases as incandescent

lamps mixed with small amounts of a halogen gas. The halogen reacts with the tungsten deposit

to produce tungsten halides, which breaks down when it reaches the hot filament.

Forming the bulb

After the glass tube is cut to length, an exhaust tube must be attached to the top. First the top

of the tube is heated using gas/oxygen fires. A tungsten carbide wheel folds the softened glass

over to form a dome shape containing a small hole.

A smaller glass tube called the exhaust tube is placed in the hole and joined to the larger tube by

melting. This small diameter tube is used as a means to flush the air out of the lamp during the

sealing operation and evacuate the air and introduce the fill gas during the exhaust process. This

process is performed on special rotary machines.

Outer leads protrude from the end of the press and provide a means to electrically connect the

lamp to the lamp base.

Evacuating and filling the pressed bulb

7 The pressed bulb is filled with the halogen gas on the exhaust machine. This machine employs

vacuum pumps to evacuate the air from the bulb and a filling system to introduce the halogen

gas mixture into the bulb through the exhaust tube. The high internal lamp pressure is achieved

by first filling the lamp above atmospheric pressure and then spraying or dipping the bulb into

liquid nitrogen which cools and condenses the fill gas below atmospheric pressure. Gas/oxygen

fires then melt the exhaust tube at the top of the bulb forming the tip and trapping the gas in

the bulb. The gas expands as it warms to the ambient temperature and thus results in a

pressurized lamp.



CABLE:

Figure??

Copper Wire Manufacturing Process

Copper metal is been largely use by copper wire manufacturers for making copper wires. Even though

the metal has to undergo various stages before it is converted into wire. The series of steps involve in the

manufacturing process of these special cables include a set of quality standards. The first step implies

mining and crushing of metal to form copper wire. Second step involves grinding of the crushed ore in

large machines that transform the metal in to powder by acting on it in cylindrical and rotating manner,

after this copper is concentrated by removing the waste slag from it. The process of copper wire

manufacturing includes series of steps. Initially it is worked upon to form copper rods which are later

transformed into wires.

The oxide ore are been leached in weak acid solution that forms a weak copper sulfate solution. This

copper laden solution is been treated in an electrolytic process tank. This process is referred to as electro

winning. The next process is referred to as smelting, the recycled copper is smelted. Heat and the

chemical reducing agents are used in the process for changing the oxidation state of copper metal. With

the purification of copper this stage results in ninety nine percent pure copper. After smelting electrolytic

refining and electro winning is done, here copper ions are electrolytically migrated from anodes to the

"starter sheets". The cathodes formed are finally casted into wire rods.

Then the wire drawing process from these rods is started, the rods are been pulled through a drawing

die. The narrower ends of the die forces the copper rod’s to shrink in diameter and be of longer length.

This process is repeated several times by making use of progressively smaller drawing dies.

After this its time for annealing process an important part of copper wire manufacturing. Contrary to the

drawing process, here heat is applied to copper metal. This process is meant for bringing the needed

flexibility to the wire. The wire has to undergo electric furnace for getting back its flexibility that is been

lost in the process of drawing. After annealing process the metal re-crystallized into its original structure.

http://www.rajasthanelectric.com/Copper_Wire.htm





By electroplating process the special cables such astinned , braided or coated wires are formed, however

technically after annealing process the wire is ready to use but there are numerous kinds of wires that

can be formed from the copper wires.



Bulb socket

Figure ?

Function

Produce bright light so users can easily move in the darkness or make other users see

the vehicle easily.

History

In fact, early electrical systems were exorbitantly expensive to install and to maintain, as well as

subject to frustrating service interruptions and frightening power surges. As a consequence, the

market for electric light during the 1880s was extremely small, and the number of bulb

receptacles or sockets produced was miniscule. During this formative period, Edison’s DC (direct

current) system dominated the market and his “Bergmann” socket was the prototypical design.

Process of making it

An injection mold for the mass production of pea-type lamp sockets having a split cavity into

which is positioned a split core carrying knife blades actuated by the swinging movement of the

split core to out completely through a central portion of an insulated wire molded into the lamp

socket body and also to strip the insulation asay from the adjacent cut ends. Upon the

longitudinal removal of the split core from the split body cavity, fiat conductors are inserted into

sockets which have been cast into the lamp socket. Such flat conductors engage and are held

permanently in electrical contact with the bared copper wires by a forced mechanical fit.



TABLE:

Part

no.

Part

name

Material Joint part Manufacturing

process

Quantity Function

1 Lens

Glass

Polypropylene,Polyc

arbonate, Nylon UV Acrylic

Cationic Cure

Epoxy

Injection molding

process

1 Cover the

inner part2 Reflector Aluminium,

thermosettingplastics

Injection molding

process

1 Reflect light

produced,

Increase light

intensity,

3 Socket Steel Mechanical

fastening

Injection molding 1 Hold bulb

4 Cable Copper wire,

insulator

solder Extrusion

molding

3 To allow the

current to

bulb

5 Frame Steel Screw and

nut

Molding process 1 Hold lens and

reflector

together

6 Bulb Aluminosilicate

glass

Quartz(silica)

Mechanical

fastening

An argon and

nitrogen mixture

is pumped in

1 Produce light

manufacturing lab report

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