HEADLAMP: REVERSE

ENGINEERING

By: Emma Reid, Andrew Rice, Eliza Roesler, and Jake Schmidt
Our Hypothesis
If we turn on the headlamp, then the circuit will be completed and energy from the
batteries will flow through, turning on the LED’s.
A
Manufacturing Analysis
How is an LED manufactured? We are going to condense this complex process into 3
easy steps!

1. A semiconductor wafer (piece of metal) is grown in a high pressure environment

& mixed with metals to form a boule.
2. The wafer is cut as needed, and metal contacts are melted on.
3. Diodes can be cleaved or sawed in a very specific process. Depending if they´re
single or series LED´s, they may be molded together.

Now they´re finished, and packaged!

D
C
Who makes the headlamp?
Lighting Ever, a company based in Las Vegas!

B
www.lightingever.com
Structural Analysis -Main Purpose
● The main purpose of the structure of the headlamp is to provide safety for the
LEDs and keep the headlamp securely on the head allowing the headlamp to
provide light for the user
Structural Analysis
● The purpose of the LEDs is to accomplish the task it was made for and create
light
● The circuit board gives information to the LEDs from the button on the top of the
headlamp
● The battery pack provides power for the headlamp
● The elastic band that is connected to each side of the headlamp secures the
headlamp so it doesn’t fall off of the user
Functional Analysis -Batteries
● Chemical oxidation reactions build up more electrons
○ Flow through cathode

● Electrolytes keep the electrons from flowing back

● Flow back through anode

Functional Analysis - Circuit Boards
● Circuit Boards direct the flow of electricity

● Resistors make sure the flow of electricity

is the right amount

● Capacitors store energy for voltage spike compression,

local energy storage, and for complex signal firing
Functional Analysis - Light Emitting Diodes
● With a current LEDs:

1) Take electrons

2) Recombine with electron holes

within the device

3) Releasing energy in the form of protons.

Functional Analysis - Miscellaneous
● On/Off Button - completes and un-completes the circuit

● Elastic Fabric - Creates a snug fit of the lamp on the head of the user
Material Analysis
● Outside of headlamp is made of various plastic (ie. PVC, polyurethane,etc.)
● 20 LEDs that illuminate when turned on (1)
● Enclosed by an epoxy and contains wire bonds, reflective cavity, semiconductors,
and plastic support) (3)
● Semi conductors made of gallium and an element in group five (1)
Material Analysis - Circuit Board and Power Source
● Hollow on inside to hold three AAA batteries (zinc and magnesium oxide) (1)
● Circuit Board (fiberglass epoxy and a copper foil bonded to both sides) (2)
● Resistors (wirewound, carbon composition, carbon film, metal film, metal oxide
film, and foil) (3)
● Elastic band of fabric to secure the headlamp to your head (2)
Was Our Hypothesis Correct?
Yes!

Through research of all of the headlamp’s parts, we found that indeed the circuit is
completed when the on button is pressed that connects to the circuit board which in
turn activates the pathway of energy flow to the LED’s.

REDESIGN?

If we were asked to redesign the headlamp, we would try to make the light attachment
smaller / more lightweight so that it could be more efficient and easier to use. It would
also be beneficial if there was a way that there could be a backup battery so that people
using this device could use it for an emergency.
Cites
Functionality Sources:
https://learn.sparkfun.com/tutorials/capacitors
https://en.wikipedia.org/wiki/Light-emitting_diode Headlamp Schematics:
http://www.qrg.northwestern.edu/projects/vss/docs/power/2-how-do-batteries-work.html http://www.next.gr/uploads/66/F
https://science.howstuffworks.com/environmental/energy/circuit.htm
WZMZ1KGD0R10NR.LARGE.jp
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Material:
(1) http://www.resistorguide.com/materials/
(2) https://en.wikipedia.org/wiki/Light-emitting_diode
(3) http://www.madehow.com/Volume-1/Light-Emitting-Diode-LED.html

Manufacturing:
(A) https://www.lightingever.com/3w-140lm-waterproof-ip44-led-headlamp-3200012-2.html
(B) https://www.lightingever.com/about-us
(C) http://www.madehow.com/Volume-1/Light-Emitting-Diode-LED.html#ixzz5QoGL9VZI
(D) http://www.off-road.com/aimages/articlestandard/trucks4x4/242009/603132/LED-labelled.jpg