5. Hardware Design

5.1 Shades

Each shade houses 252 tightly-packed LEDs, which are arranged in a hexagonal beehive-like shape. LED colors are radially symmetric. See Figure 1.31

Figure 1.31: Color LED layout; view of LED lenses (concave side) Click to enlarge

Figure 1.32: Rear View of LED Lamp shade. Each shade is connected to the base of the Lamp with 3 wires. The serial signal from the base is decoded in the shade. Click to enlarge

Figure 1.33 Click to enlarge

Figure 1.34 Click to enlarge

5.2 Aluminum Dome

For the LED shade domes, steel ladles and chrome bowls were tested but found too difficult to machine. Aluminum ladles were finally used (see Figure 1.35).

Figure 1.35

5.3 Control Panel Module

The control panel module contains all circuitry for control buttons and the touchpad. The raw touchpad is pressed into the plastic shell of the control panel. Wires are soldered to the touchpad's connector - unfortunately, Synaptics was not able to provide additional hardware, such as specialty connectors and cables. Instead, an off-the-shelf packaged mouse products were used, dissembled, and modified to fit the needs for this project.

Figure 1.36 Click to enlarge

5.4 Base Milling

The elliptical base was machined from several aluminum plates. Due to its irregular size, a CNC (Computer Numerically Controlled) machine was used to cut the ellipse out of the raw plates. For the grooves and overall convex shape of the top plate, a round 1" mill bit cut the material in elliptical paths. 2D models of those paths are shown in figures 1.37 and 1.38.

Figure 1.37 Click to enlarge

Figure 1.38 Click to enlarge

5.5 Interior

Figure 1.39 Click to enlarge

Figure 1.40 Click to enlarge

Figure 1.41 Click to enlarge

Figure 1.42 Click to enlarge

Figure 1.43 Click to enlarge

Figure 1.44 Click to enlarge

5.6 Flexible Tubing

The choice of flexible proved difficult - most off-the-shelf microphone arms proved too stiff, and lacked proper dimensions. Custom-made tubing by Vermont Flexible Tubing was found most fitting in quality, while the company was accommodating to the small individual order.

5.7 Flexible Tubing Interface

Both ends of a flexible tube need to be screwed into their respective parts. However, some parts of the LED Lamp were not rotatable in themselves, and as a result, only one of the ends could be attached. The flexible tube between the first interface and the lower leg is an example. An interface was necessary that would mount the second end on the LED Lamp. Figure 1.45 shows 2D and 3D models of the custom-designed interface.

Figure 1.45 Click to enlarge