Introduction: Homage to Duchamp's Bicycle Wheel - a Dual Mode Led Lamp (DC Hub Generator or AC Plugin)
In honor of the 100th year of Marcel Duchamp's most famous "ready made" creation, the bicycle wheel lamp and generator.
This is a dual mode led lamp for plugging in an AC LED bulb or spin it yourself for powering DC LEDs (with battery backup.) Choose the green option with Cree's latest LED 9.5 watt light bulb or go greenest with your own power. And be prepared for electric outages by spinning the updated duchamp bike wheel with its electric hub motor wheel. As the wheel spins it generates and stores electricity in a battery underneath the seat. Flip the DC switch and the battery powers 3 x 2 watt leds at the base of the lamp.
Hub motor & wheel - look on craigslist / any used bicycle electric assist hub motor should work, (this was a used golden motor mini)
http://www.goldenmotor.com/ - the most common failure for hub motors are broken hall effect wires. As a hub motor used for a generator does not need the hall effect wires, you can often pick up a used hub motor very inexpensively.
hub motor controller - virtually all bicycle hub motors are DC brushless. They come with a controller box which includes use a bridge rectifier. The controller will use the bridge rectifier (when you manually spin the motor) to convert your work to DC voltage which will charge a battery pack. Any used DC brushless electric bicycle hub controller should work. craigslist or http://www.goldenmotor.com or ebikes.ca
battery pack - plastic holder for 8 D cell batteries. (Amazon), 8 NiCad D Cell batteries (Amazon).
LED light bulb - Cree (home depot)
wooden stool - various (recommend Goodwill, Salvation Army)
bicycle fork - various (recommend Goodwill, Salvation Army)
1/4 piece of bike rim, wood plank,
2 watt lumen leds - (any bright white led will work). 2W 160-180LM 2850~3050K Warm White LED Light Bulbs (20-Piece Pack)
USD$ 7.67 (only use 3 of 20) source Dealextreme
star pcb boards - Hexangular PCB Boards for 1W/3W/5W LED Emitter (100-Piece)
USD$ 6.94 (only used 3 of 100) source Dealextreme
analog volt meter 0-30 volts ($7.00) (amazon)
bulb type lamp shade holder (amazon),lamp shade (target)
others - lamp base with pull switch (home depot), Solder, wire, chipquick solder paste (amazon), thermal epoxy, power cord with built-in switch (home depot), 1" x 8" sheet aluminum flashing scrap (home depot)
Step 1: Underside of Stool
In the center of wood stool, drill 1 inch hole for bicycle fork, 1/4 inch hole for wiring.
Mount the hub motor controller and 8 cell battery pack (each nicad = 1.2 volts, total ~9.6 volts)
Connect the output wires (typically 3) of the hub motor to the hub motor controller. This would typically be the output for an electric bike assist. Instead it is now the electric input IN to the hub motor controller.
Connect two hub motor battery wires two battery wires (red to red + , black to black-).
(Again for an electric bike the electricity would be flowing from the battery to the hub motor controller but for our setup (now a generator) this will be reversed. When you spin the wheel electricity will be flowing from the controller to the battery.)
Step 2: Build the Three Led DC Light Band - 9.6 Volts - (6 Watts ~480 Lumen)
All credit should go to DJJules for this.
Mount the led emitters to star pcb boards using chipquick solder paste and an electric skillet. See directions here or here.
After wave soldering is completed, solder the leds (now mounted on the star pcbs) in series (- to +) and thermally epoxy to 1" x 8" strip of aluminum. After drying form aluminum into a ring and epoxy onto AC light bulb fixture.
Step 3: Complete the Light - Wire Standard AC Socket + DC 3 LED Light
Wire the AC socket to AC plug in power cord.
Wire the 3 LED DC light through a switch and to the 9.6 volt battery pack.
Step 4: Analog Volt Meter - Avoid Over/under Charge
Mount the analog volt meter to the rack with a and wire to the battery pack.
Step 5: Plug in or Spin the Wheel - Enjoy
If desired add a crank and a chain to increase the gearing and speed up charging.