Developed by Sean O Connor

Developed by Sean O Connor

This project provides pupils with the opportunity to design a desktop light based on the use of a copper pipe. They will be asked to solve the problem of how to fix the pipe at an appropriate angle using a second material. Materials: 15mm Copper pipe with the option of hard wood, 5mm acrylic or a sheet metal.

Your Brief: To design and manufacture a USB power desk light. Your design must be manufactured from the following: Material Sheet metal Copper pipe Hard Wood Acrylic PCB (Printed Circuit Board) Workshop equipment Drill Hack Saw Pipe Bender Pop rivet gun Sheet Metal Folder Guillotine Files Emery paper Task: Identify key features of the light that need to be addressed: You must know what problems/features you could add. Annotate the picture and detail the areas for focus

Angle of the pipe Fixing the PCB to the pipe Your Brief: To design and manufacture a USB power desk light. Your design must be manufactured from the following: Material Sheet metal Copper pipe Hard Wood Acrylic PCB (Printed Circuit Board) Workshop equipment Drill Hack Saw Pipe Bender Pop rivet gun Sheet Metal Folder Guillotine Files Emery paper Fixing the copper pipe Bending the pipe at the require curvature. Task: Identify key features of the light that need to be addressed: You must know what problems/features you could add. Annotate the picture and detail the areas for focus

Research Now research images that are associated with this type of product or similar products. Focus your research on the areas identified on the previous page. As a designer research is key to developing a successful outcome, sourcing inspiration in the form of colours, features, form, materials, e.t.c from existing and similar products. Task: Now cut and paste images onto this page and create a mood board

Research Teacher guidance material Now research images that are associated with this type of product or similar products. Focus your research on the areas identified on the previous page.

Design Now generate concepts to resolve the following problems: By breaking down the problem into aspects it then becomes easier to manage/solve. Fixture for the PCB Fixture for the pipe Solve this problem using side elevation. This fixture must hold the pipe at the appropriate angle. 3D sketch or CAD model Once the problems have been solved using the side elevation, generate a 3D view.

Design Teacher guidance material Now generate concepts to resolve the following problems: By breaking down the problem into aspects it then becomes easier to manage/solve. Fixture for the pipe Solve this problem using side elevation. This fixture must hold the pipe at the appropriate angle. 3D sketch or CAD model Once the problem has been solved using the side elevation, generate a 3D view

Design Teacher guidance material Now generate concepts to resolve the following problems: By breaking down the problem into aspects it then becomes easier to manage/solve. Fixture for the PCB Fixture for the pipe Solve this problem using side elevation. This fixture must hold the pipe at the appropriate angle. 3D sketch or CAD model Once the problem has been solved using the side elevation, generate a 3D view

Acrylic blank Design Sheet metal or acrylic solution TASK: Accurately draw the Copper Light design in the space provided. The drawing will require the following detail: Outline to be cut solid line. Mark with a cross any holes required. Mark the bend lines - dotted line. You will also need to work our the curvature of your copper pipe, use the line above as a guide.

Design Sheet metal and acrylic solution Now pull your concepts together generating a front, side and 3D views of the finished concept. Acrylic blank ants TIP: Card could be used to model concept and also used as a template for marking material for manufacture.

Design Teacher guidance material Now pull your concepts together generating a front, side and 3D views of the finished concept. ants

Acrylic blank Design Wooden base solution TASK: Accurately draw the Copper Light fixture/base design in the space provided. The drawing will require the following detail: Outline to be cut solid line. Mark with a cross any holes required. You will also need to work our the curvature of your copper pipe, use the line above as a guide.

Design Now pull your concepts together generating a front, side and 3D views of the finished concept. Acrylic blank ants

Design Teacher guidance material Now pull your concepts together generating a front, side and 3D views of the finished concept. ants

Bending Tube bending is a metal forming process used to permanently form pipes or tubing into the shape of a die. Straight tube can be formed using a bending machine to create a variety of single or multiple bends and to shape the piece into the desired form. This process can be used to form complex shapes out of different types of ductile metal tubing. However, if the metal tube is not bent properly it will collapse leaving the wall of the pipe wrinkled and deformed. When bent the metal is work hardened. Rotary benders Here we can see a hand held rotary bender. You simply place the pipe in the rounded channel. Fit the grooved straight block on the outer edge. Use the lever handles to apply pressure against the straight block. Now continue levering so that it gradually draws the pipe around the circular block, bending the pipe as it goes. Bend to the desired angle, then release the handles to remove the pipe. Typical products that are formed like this. Flexible springs The simplest method of bending a pipe is to us a flexible spring inserted into a pipe to support the pipe walls during manual bending. The spring stops the pipe form collapsing inside. They have diameters only slightly less than the internal diameter of the pipe to be bent. The spring is pushed into the pipe until its centre is roughly where the bend is to be. The pipe is generally held against the flexed knee, and the ends of the pipe are pulled up to create the bend. They are less cumbersome than rotary benders, but are not suitable for bending short lengths of piping.

Design TASK: Generate your own PCB layout. Ensure you connect the LED s correctly. Draw your circuit layout ideas: Below is the circuit you need to recreate in the shape you desire. Teacher guidance material Tip: Pupil s may wish to make different shaped PCB s to improve the aesthetics or vary the lighting of the product. More LED S could be added. Convert your circuit to a PCB layout: Normal View Integrating Your light with USB Your circuit is powered by the 5V and 0V supply on the USB lead. These Red and black wires are normally used to power external devices, (IPod, pen drives etc) the other wires which you will not use are required to transfer data to and from these external devices. Real life View

Design TASK: Generate your own PCB layout. Ensure you connect the LED s correctly. Tip: Pupil s may wish to make different shaped PCB s to improve the aesthetics or vary the lighting of the product. More LED S could be added. Draw your circuit layout ideas: Below is the circuit you need to recreate in the shape you desire. Teacher guidance material http://www.kitronic.co.uk/ Convert your circuit to a PCB layout: Normal View Integrating Your light with USB Your circuit is powered by the 5V and 0V supply on the USB lead. These Red and black wires are normally used to power external devices, (IPod, pen drives etc) the other wires which you will not use are required to transfer data to and from these external devices. Real life View

Manufacture Task: With the help of the pictures detail step by step how you intent to manufacture your product. State materials, machines and equipment used. Annotate pictures if necessary. 1. 1 2. 3. 3 2 3 4. 5. 4 6. 5 7. 7 8 8. Test 6 9

Manufacture 1. Cut the copper pipe with a hack saw. Teacher guidance material 1 2. Insert the spring and place the copper pipe onto the holding bar. (alternatively a rotary bender or filling the pipe with sand can be used to stop deformation) 3. Using another bar for leverage bend the pipe to the desired curvature 4. Crimp the end of the copper to allow the PCB to be inserted. (push tight fit required) 2 3 5. Sand, drill, Populate and solder PCB. 4 6. Insulate the solder side of the PCB neoprene foam (fix with double side tape). 7. Insert the USB cable through the centre of the copper pipe and solder to PCB 7 5 8. Push the PCB into place Test 6 9 8

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