The LED Torch – Introduction – Planning your project

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MarcScott

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The LED Torch – Introduction – Planning your project

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LED_Torch

A KS3 Project to design and build an LED Torch

On Github MarcScott / LED_Torch

The LED Torch

Created by Kevan Wacket using reveal.js The LED Torch by Kevan Wacket is licensed under a Creative Commons Attribution 3.0 Unported License.

CONTENTS

Introduction Planning your project Resistors LEDs Plastics Components Drilling the PCB Soldering the PCB Assembling the torch Designing the circuit Designing the PCB Designing the housing Writing up your portfolio

Introduction

A company has been asked to design and make a pocket-sized device that can aid people to see the keyhole for their car and front door in the dark. Lighting & inspection personnel specialists (liPS) have produced a pocket sized LED torch that will fit onto a key ring, so will always be at hand. They have passed this design onto Bourne Grammar School to design the PCB and create the finished product.

Your task is to research into components and create a PCB that will fit into the casing of the Torch, re-design the case on 2D techsoft, so that it can be precision cut on the laser cutter, assemble and finish the product to the high quality standard that LiPS are renown for.
To create the product to the high standard that is required you need to research into a few areas first, below is a spider diagram of things you need to research.

Research plan summary.

You'll need to research the different subject areas as previously. To keep your research focussed you will try to look at them in the following order:

Resistor - What it is, what it does, what a resistance is, is there a circuit symbol for it. LED - What it is, what it does, is there a circuit symbol for it. Plastics and fixings - What categories, how to fix them together. Circuit - What is a circuit, how do you make a circuit, what is a PCB, how do I make a PCB. You will put all my findings into a portfolio to help manage the project. You can use the portfolio as part of a pitch to the client explaining how you reached the design and final product.

Planning your project

The Plan

To complete this project successfully and to a high enough standard that is acceptable of any good craftsman, you must be wise with your time.

You will only have 6 x 1 hour lessons in school, so therefore you are trusted to complete this project in your own time at lunch, at home or both.

Gantt charts

Gantt charts help you to plan your project and to keep to deadlines.

Below is an example Gantt chart. You simple place crosses in the box for each task showing the dates you will be working on it.

Your own Gantt chart

Download the Gantt chart here

You need to fill this in and try and keep to the deadlines you set. It will be useful for you to review your Gantt chart at the end of the project to help evaluate how you managed your time.

Resistors

Colour codes

Colour codes

When reading a resistor, hold it so the three colour bands that are close together are on your left, you now read the bands from left to right.

So therefore this resistor value is 560 ohms + or – 28 (5%) This equals a value between 532 ohms and 588 ohms

Resistors

Download worksheet and complete it to consolidate your learning on Resistors.

LEDs

LEDs

LED is an acronym for Light Emitting Diode.

As well as emitting light when current passes through an LED, they only allow current to flow one way.

LEDs and Current Flow

Conventional current flows from positive to negative, so we must make sure we place our diodes in a circuit the correct way around. We connect the anode to the positive and the cathode to the negative.

LEDs Worksheet

Download worksheet and complete it to consolidate your learning on LEDs.

Plastics

Types of Plastic

There are two types of plastic. You're going to need to do some research on plastics using the Web and any other resources you can find.

Download and fill in this document on plastics.

Components

Components task

Download this documentYou'll need to complete the table provided by finding names, circuit symbols and images of the components used in your project.

Drilling your PCB

What you'll need to do

Clean the PCB and drill the correct size holes. Take pictures for your portfolio Write about what you have achieved at this stage. Explain in detail, label the picture and use keywords correctly.

Tutorial

Soldering your PCB

What you'll need to do

Select the right components Place them on the board the correct way round Remember that some components have a positive and negative Solder them onto the tracks Take pictures for your portfolio Write about what you have achieved at this stage. Explain in detail, label the picture and use keywords correctly.

Step-by-step guide

The switch will only fit one way, with the legs of the switch facing towards the shorter sides of the PCB. The LED is 3mm in size, and must be soldered with the LED flush against the top side of the board. LEDs are polarised so must be soldered the right way around. The positive (longer) leg of the LEDs must be soldered to a “+” LED pad on the PCB. The 1 Ω Resistor can be positioned either way Strip and solder around 5cm of solid core wire in the holes marked +3v and – (these will be used to connect to the batteries within the case)

Diagram

Tutorial

Assembling your torch

What you'll need to do

Collect all five pieces of acrylic, M3X12 screws, screwdriver, adhesive copper track and tensol glue. Take pictures for your portfolio Write about what you have achieved at this stage. Explain in detail, label the picture and use keywords correctly.

Tutorial

Cleaning and polishing

When your torch is assembled talk to your teacher about cleaning and polishing the edges, (there is no tutorial for this). Take pictures for your portfolio Write about what you have achieved at this stage. Explain in detail, label the picture and use keywords correctly.

Designing your Circuit in Circuit Wizard

What you'll need to do

Using circuit wizard, create a circuit that will switch an LED on and off, using a PTM switch, LED, Resistor and 3V battery. Save in your LED torch directory Print screen it for your portfolio When using this in your portfolio, explain what you did to create it. Write about the different components, where you found them and what they do/how they work

Tutorial

Designing your PCB in Circuit Wizard

What you'll need to do

Using circuit wizard, create a PCB from the circuit you have drawn. Save in your LED torch directory Print screen different views for your portfolio When using this in your portfolio, explain what you did to create it. Write about the ‘artwork’, ‘real life’ and the with/without components tabs.

Tutorial

Designing your Torch Housing

What you'll need to do.

Draw the pieces of your torch on 2D design Put your name on the bottom piece Save in your LED torch directory Print screen it for your portfolio When using this in your portfolio, explain what you did to create it. Write about the drawing tools, the delete tools, the grid and the toggle tool.

Introduction to TechSoft 2D

Tutorial

Writing your portfolio

What you'll need to do

You need to download this portfolio template. Complete the document as shown in step 1.

Last steps

Proof read your work, get someone else to proof read your work (an adult that looks after you) work to the ‘green pen’ system. Have it ready to hand in on the deadline set by your teacher at the beginning of the project.

Extension

Solidworks

As an extension task, you could have a go at creating a 3D model of your torch in Solid Works. Your teacher will be able to guide you or there is a lunchtime club you can join. Only do this when you have completed all tasks set and are satisfied you have ‘green-penned’ your work.