Custom LED Brake Light

[bobvans]

Got the board mounted.  Next step is to get it connected to the bike and test it out before I button it up.


Mounted.jpeg (57.09 kB . 768x576 - viewed 465 times)

[bobvans]

Drivers regularly crash into lit up police cars parked on shoulders. In attempts to avert that, intermittently flashing, rather than pulsating, strobes have been developed. There's a body of evidence that suggests pulsating strobes can attract some drivers rather than alert them. It's a jungle out there. 

That's interesting, thanks for sharing!  The strobe/flash pattern is selectable so I'll have to choose wisely.  It's also good to just be aware of who's coming up behind you and leave an escape route.

[bobvans]

Got the tail light wired up and did a comparison between my original (which used LED replacement bulbs) and the Custom LED version.

Day Time Comparison - the running light was barely noticeable...



And at night and a little further back...

[bobvans]

Here are the things that can be adjusted...

1 - Start sequence that comes on when ignition is turned on can be turned on or off
2 - The brake alert pattern can be changed (see the 11 options early in the thread)
3 - The running light brightness can be adjusted within a preset range
4 - The brake light brightness can be adjusted within a preset range

I haven't played with the brake patterns yet... but I do want to change it to something else.  The standard pattern is 4 quick strobes then solid.  I find the 4 strobes to be too fast.

[Laitch]

That's an excellent outcome! Thanks for a thorough presentation and video of this project. 

[bobvans]

That's an excellent outcome! Thanks for a thorough presentation and video of this project. 

I've received and pulled so much helpful information from this forum that it just seems appropriate to give a little back. 

The custom LED board cost me $441 but that includes the design work.  I was told subsequent orders would cost less.  I can't remember the number he gave me but seem to think it was around $140 or so.

[bobvans]

Now that I know the electronics work, I went ahead and hot glued the red lens to the housing.  Used a tooth pick to set a small gap between the red lens and the white housing to give the hot glue something to go into.  It's about the size of the gap created by the Dremel so this should also get the overall size close to original.


Completed.jpeg (55.69 kB . 768x576 - viewed 389 times)

With the board spanning across the entire tail light, the ends are open to the environment.  I know the tail light doesn't seal against the rear cowl so leaving it open is a bit of a concern.  I don't drive in the wet if I can avoid it but sometimes you can't avoid it.  I may play around with adding side walls.


Side View.jpeg (45.59 kB . 768x576 - viewed 454 times)

[AtLarge]

That's a big improvement!  Make sure it can drain at the bottom if water could get in there.  You could use a sealant or potting material to coat the PCB then it would be protected too.  Makes repairs in the future a lot harder though.   

[bobvans]

That's a big improvement!  Make sure it can drain at the bottom if water could get in there.  You could use a sealant or potting material to coat the PCB then it would be protected too.  Makes repairs in the future a lot harder though.   

Good suggestion... I was thinking something similar, use something to fill in the ends.  I'll look at what I can do.  Thanks!

[rbm]

If you are planning to produce these in bulk, then I'd suggest looking into JLCPCB.com.  They are a PCB manufacturer and they also do assembly work.  They take your design and construct the board, then populate it with components you select from their parts supply house, LCSC.com.  You pay by the size of the board but overall it is the cheapest option for you.  Its the service I use for my electronic projects.

Now that you have a working prototype, you might want to consider moving from through-hole technology to surface mount technology.  You'll open up a whole new world of design and manufacturer flexibility.  Did the guy who designed the board for you give you the design files (or just the Gerbers)?

[bobvans]

Now that you have a working prototype, you might want to consider moving from through-hole technology to surface mount technology.  You'll open up a whole new world of design and manufacturer flexibility.  Did the guy who designed the board for you give you the design files (or just the Gerbers)?

I got the board thru Custom LED who sells LED tail light assemblies for motorcycles.  They designed the PCB mechanicals to my specs (board outline, mounting holes, wiring location) but it's their circuit design and their code.  I reviewed their layout and made a few alterations.  The board was delivered fully assembled and tested.

[bobvans]

A side by side compare...


AB Compare.jpg (45.35 kB . 438x576 - viewed 422 times)