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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.
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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 )
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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