finish post (closes #12)
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@@ -1,7 +1,7 @@
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categories = ["build"]
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tags = ["bicycle"]
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date = 2025-08-07T08:00:00-05:00
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date = 2025-08-12T12:15:00-05:00
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description = ""
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draft = false
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slug = "bicycle-headlamp"
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@@ -14,7 +14,7 @@ Nighttime bicycle rides in the summer are ideal:
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- 🚘 little traffic
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- 🦝 nocturnal wildlife
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But it is not easy to see in the dark, so I bring a headlamp and okay, fine, this works. With my current head lamp I can see and be seen just fine. But there are some limitations. I see wonderfully directly ahead of me in the narrow cone of light provided, but at the edges of this light cone I see practically nothing at all, as though I am looking through a paper towel roll. The beam pattern is optimized for riding in a straight line, with little regard for what lies in the periphery. **I would like a greater field of view, so I will need a lamp with a wide beam pattern.**
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But it is not easy to see in the dark, so I bring a headlamp and *okay, fine, this works*. With my current headlamp I can see and be seen just fine. But there are some limitations. I see wonderfully directly ahead of me in the narrow cone of light provided, but at the edges of this light cone I see practically nothing at all, as though I am looking through a paper towel roll. The beam pattern is optimized for riding in a straight line, with little regard for what lies in the periphery. **I would like a greater field of view, so I will need a lamp with a wide beam pattern.**
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## 🔦 Headlamp
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I start by selecting the headlamp. This is the most important component, and everything will revolve around it. My selection criteria is simple. The light must have these features:
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@@ -36,11 +36,19 @@ I had to settle for the **OPL5 Motorcycle LED Headlamp**:
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| Brightness | 3000 lm |
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| Color Temperature | 6500K (Cool White) |
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✅ **This will have to do**.
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{{< image src="images/opl5-motorcycle-led-headlamp.png" >}}
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{{< image
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src="images/beam-pattern.JPG"
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caption="OPL5 Beam against the wall" >}}
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Notice the sharp beam cutoff at the top. This is what allows me to have a very bright headlamp while also not blinding oncoming traffic. Also, the beam gradient at the bottom transitions from very bright to very dim, in a manner that maximizes usable light. It concentrates maximum light near the upper cutoff where it will disperse across a large surface area at long distances, while minimizing output in the near and mid field, where the illuminated surface area should be relatively small.
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✅ **This will do**.
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---
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## 🧰 Case
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@@ -62,7 +70,7 @@ Since the headlamp consumes 48 W, I need a battery that can sustain this load fo
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- $t$ = run time (hr)
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- $E_\text{battery}$ = battery energy (Wh)
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- $p_\text{load}$ = LED headlamp power (W)
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- $P_\text{load}$ = LED headlamp power (W)
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$$
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t = \frac{12.8 \text{ V} \cdot 16 \text{ Ah}}{48 \text{ W}} = 4.27 \text{ hr}
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@@ -113,6 +121,10 @@ Now for final assembly. This is all very simple and I ran into no issues.
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- Sealed the power port and switch mounting holes with silicone
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- Removed the battery enclosure lid since the battery terminals were ≈ 1 mm proud of the battery box lid. The battery box would still close, but it was straining the plastic and the weather sealing would be compromised.
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{{< image
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src="images/battery-box-open.JPG"
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caption="Battery box inside" >}}
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Here is a **wiring diagram** of the circuit.
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{{< image src="images/bicycle-headlamp-wiring-diagram.svg" >}}
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@@ -124,16 +136,32 @@ Here is a **wiring diagram** of the circuit.
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| SW1 | SPST Switch |
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| LED1 | 48 W |
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I strap the battery box to the rear cargo rack with hook and loop straps.
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That is all.
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{{< image
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src="images/battery-box-power-port.JPG"
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caption="Battery box power port" >}}
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--
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{{< image
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src="images/battery-box-switch.JPG"
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caption="Battery box switch" >}}
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{{< image
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src="images/battery-box-mounted.JPG"
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caption="Battery box fastened to the rear cargo rack with hook and loop straps" >}}
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{{< image
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src="images/headlamp-mounted.JPG"
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caption="Headlamp on handlebars" >}}
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---
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## 🚴 Test Drive
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All that remains is the test drive.
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{{< image src="images/headlamp-night-test-drive.jpg" >}}
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{{< image
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src="images/headlamp-night-test-drive.jpg"
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caption="Wide beam width" >}}
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🎉 **It works!**
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