Direct Factory Dual Beam Bicycle Front Light Quotation
Direct Factory Dual Beam Bicycle Front Light Quotation
This lighting system uses two independent LED arrays to produce a wide‑angle flood beam and a focused spot beam from a single housing. Each array is driven by a constant‑current driver that maintains
- Categories:Bicycle Front Light
Direct Factory Dual Beam Bicycle Front Light
This lighting system uses two independent LED arrays to produce a wide‑angle flood beam and a focused spot beam from a single housing. Each array is driven by a constant‑current driver that maintains luminous flux within ±5% across the input voltage range of 6‑8.4 V DC.
The flood beam provides a minimum illuminance of 12 lux at 5 m distance, measured on a white surface, while the spot beam delivers a peak intensity of 85 cd at the optical axis. Both beams are optically isolated to prevent cross‑talk, ensuring consistent color temperature of 6000 K ± 200 K.
Electrical & Power Characteristics
Input power is limited to 2.4 W maximum, with an efficiency of 88% at nominal 7.2 V operation. The driver includes over‑voltage protection up to 10 V and reverse‑polarity tolerance to prevent damage during installation errors.
A built‑in lithium‑ion cell (optional) provides 2.5 Ah capacity, enabling up to 4 hours of continuous dual‑beam operation at full output. Charging is performed via a 5 V USB‑C port with a charge current limit of 0.5 A.
Mechanical Design & Materials
The housing is machined from 6061‑T6 aluminum alloy, featuring a hard‑anodized finish (thickness ≥ 12 µm) for abrasion resistance. Sealing is achieved with an IP‑68 rated silicone gasket and a threaded front lens retained by a stainless‑steel retaining ring.
Overall dimensions are 45 mm × 30 mm × 28 mm (L × W × H) and the mass is 42 g without battery. Mounting is accomplished via a M5 × 0.8 mm threaded boss that accepts standard bicycle fork crown adapters.
Thermal Management
Heat generated by the LEDs is transferred to the aluminum body through a direct‑bonded copper‑core PCB (thermal conductivity ≈ 380 W/m·K). Steady‑state temperature rise of the LED junction is limited to 35 °C above ambient at 2.4 W dissipation.
Fin geometry on the housing exterior increases surface area by 22 % compared to a smooth cylinder, reducing surface temperature by approximately 4 °C under forced convection equivalent to 2 m/s airflow.
Typical Applications
- Road cycling where a wide flood beam improves peripheral vision and a focused spot beam illuminates distant obstacles.
- Off‑road mountain biking requiring robust sealing against mud and water immersion.
- Urban commuting with frequent stop‑start cycles benefitting from instant‑on constant‑current drive.
- Night‑time maintenance or inspection tasks on bicycles where hands‑free illumination is needed.
Customization Options
Beam angles can be adjusted by swapping interchangeable optics: flood options from 20° to 40° full width at half maximum (FWHM) and spot options from 8° to 15° FWHM.
Housing color is available in natural aluminum, black anodize, or custom powder‑coat RAL values upon request. Cable length and connector type (JST, Molex, or bare leads) can be specified to match OEM wiring harnesses.
Optional integrated light sensor enables automatic dimming based on ambient lux levels, with a programmable threshold range of 5‑50 lux.
Quality Assurance & Testing
Each unit undergoes a 100 % functional test verifying luminous flux, beam pattern, and driver regulation. A sample of every production lot is subjected to IEC 60529 IP‑68 immersion testing (30 min at 1 m depth) and thermal cycling (−20 °C to +60 °C, 10 cycles).
Documentation includes a test report with measured values for flux (lm), intensity (cd), and temperature rise (°C). Traceability is maintained via laser‑etched serial numbers on the housing interior.
Specification Table
| Parameter | Value / Range | Condition |
|---|---|---|
| Input Voltage | 6.0 – 8.4 V DC | Nominal |
| Maximum Power | 2.4 W | At 8.4 V |
| Flood Beam Illuminance | ≥ 12 lux @ 5 m | On white surface |
| Spot Beam Peak Intensity | ≥ 85 cd | On axis |
| Color Temperature | 6000 K ± 200 K | Both beams |
| Housing Material | 6061‑T6 Aluminum | Hard anodized |
| Ingress Protection | IP‑68 | 1 m, 30 min |
| Mass (no battery) | 42 g | – |
Quotation Process
To obtain a formal quotation, provide the required annual volume, target delivery schedule, and any specific customization options (beam angles, housing finish, cable length, connector type). Our engineering team will review the request and return a detailed price breakdown within two business days.
Tooling costs are amortized over the production run; no upfront NRE is charged for standard optical configurations. For custom optics or special finishes, a one‑time tooling fee will be itemized in the quotation.
Frequently Asked Questions
A: Yes, with an appropriate rectifier and voltage regulator to maintain 6‑8.4 V DC; the driver includes over‑voltage tolerance up to 10 V.
A: Typically 500 units; lower quantities are available upon request with a setup surcharge.
A: Using an integrating sphere calibrated to CIE 127:2007, reported in lumens with an uncertainty of ±3 %.
This lighting system uses two independent LED arrays to produce a wide‑angle flood beam and a focused spot beam from a single housing. Each array is driven by a constant‑current driver that maintains
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