Project EMERALD log! (SWM F30R mod)

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tterev3
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Project EMERALD log! (SWM F30R mod)

I’m starting a big project called EMERALD: Everett’s Multicolor Enhanced Really Awesome Lighting Device. I’ll post updates to the project as I go in this thread. I’m keeping things a bit nebulous until you see the finished product; see if you can guess what it’ll be like! I will tell you this: you know I’m insane when I think I need a light that does even more than MELD does.

This project will be based on a Sunwayman F30R, so part one of this build log is the teardown:

ring of 3mms on their daughter board

inner pill comes out by unscrewing the ring

all apart

driver exposed

As usual I am very impressed with the build quality of Sunwayman lights, and I’m happy to see that there is plenty of room in here to do what I have been planning…

Well, now that I know how big the board is, it’s Eagle time! stay tuned

Edited by: tterev3 on 09/24/2014 - 14:21
tterev3
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This project has been finished for a while but I’ve been terribly lazy about putting up a video! Here’s a quick demo of the finished project. I didn’t go into any detail about the modes since most things function the same as MELD (which you can see here: http://youtu.be/B09tLW9JaXI), so this mostly discusses the things that are different for this two-button version of the firmware:

Cereal_killer
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Nice name lol. Mine will be here Monday (and my V11r came today).

Really impressed with what I can see of the pill/heatsink, that’ll make my job easier, good job SWM!

 

Always remember SPC Joey Riley, KIA 11/24/14.

MRsDNF
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I like Emerald.Smile

My current and or voltage measurements are only relevent to anything that I measure.

Budget light hobby proudly sponsored by my Mastercard and unknowingly paid for by a hard working wife. 

djozz said "it came with chinese lettering that is chinese to me".

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

Mattaus
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Nice little host. Not too sure where you can go after MELD... I suppose the host was chosen for a reason with all those little 3mm LEDs. Wonder how many XQ footprint LEDs you can fit in each 3mm space?

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Pulled up a chair, brought some tasty snacks and refreshments, this is going to be good.

tterev3
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First update: here’s my first draft of the schematic for the new driver

Mattaus
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So main white channel, blue, red, green, IR, and two separate UV wavelengths. Nice.

Questions:

- How do you plan to use the host? Color mixing will not be very good unless done in the main reflector I'd think.

- Still using a voltage regulator for the color/IR/UV emitters, yes?

- Do you think the two UV wavelengths are too close together? They will more or less be used for the same thing?

- What level are you driving the main white emitter at (no value on R7)?

- What UV and IR emitters are you using? I want to get my hands on some emitters like this as well so if we can save bucks and do a group buy please mention something on these forums!

Sorry for so many questions. Your projects are always pretty close to home for me so I really like to see how you do things for my own learning process Smile

- Matt

saypat
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where is the order form?

MRsDNF
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+1 on what Matt asked and said. Embarassed

My current and or voltage measurements are only relevent to anything that I measure.

Budget light hobby proudly sponsored by my Mastercard and unknowingly paid for by a hard working wife. 

djozz said "it came with chinese lettering that is chinese to me".

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

tterev3
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Mattaus wrote:

- How do you plan to use the host? Color mixing will not be very good unless done in the main reflector I’d think.


I want to keep it with the original arrangement and use the reflector for white only. You’re right that the beams won’t be great, but 99% of the use will be on white so I put much more importance on that beam being perfect. I’m hoping I can find some optics that will fit in the space between reflector and outside wall so I can get something halfway decent on the color emitters. It will also help that for R, G, and B I can have 2 emitters opposite each other so at least it won’t be off-center.

Mattaus wrote:

- Still using a voltage regulator for the color/IR/UV emitters, yes?


Yes, I chose a new buck-only CV regulator for this one that can supply up to 3A, and each color emitter will use a resistor to set current.

Mattaus wrote:

- Do you think the two UV wavelengths are too close together? They will more or less be used for the same thing?


In my experience 405 and 380 act very different, but maybe I haven’t seen other options. Do you know of any emitters that go much shorter than 380?

Mattaus wrote:

- What level are you driving the main white emitter at (no value on R7)?


The buck regulator for the white channel is fairly devoid of details because I happen to have a bunch of boards in my scrap bin that have a complete MAX16820 setup, and I plan to salvage all the components. I think the values are 0.068 which gives about 3A.

Mattaus wrote:

- What UV and IR emitters are you using?


For the 405nm, I’ll use the Luxeon UV. For the 380, I have a LED Engin LZ1 that I think is 380 (it may be slightly lower). I would prefer to use the Lux UV for both because its package is more convenient, but I think the LZ1 I have is shorter wavelength than Luxeon offers. I’m not 100% sure which I’ll use. For IR I have an Osram Golden Dragon—unfortunately large package but the best high-power IR emitter I’ve used.
tterev3
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getting started on the layout, looks like I’ll need to do a daughter board to make it fit:

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Thanks for the explainations Smile

In regards to the UV and IR LEDs, LEDEngin make two that I'd personally use:

The LZ1-10U600 36nm UV LED

and

The 850nm LZ1-10R400 IR LED. Much smaller package than the Golden Dragon.

The IR price is OK, but the UV price sucks (and cutter only sell in lots of 10 with Mouser et all being much more expensive).

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joined the audience Smile

The LZ1 comes in 365nm as well, but those Luxeons are so small and elegant, and go as low as 380nm as well.

tterev3
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This morning’s layout progress. Got the weird tri-lobe board edge in and did some component grouping:

tterev3
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started the main & daughter boards. got the outlines set and basic component arrangement established. here’s the current challenge: locating the 4 pins that pass from main up to daughter while avoiding impeding on the space for battery contacts and the shelf (exposed case material, must be unmasked copper) regions.

Mattaus
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I can recommend Mill-max pins for PCB interconnects. They'll give you the cleanest connection. They also have an insanely large range...

https://www.mill-max.com/product_finder

They do through hole, surface mount, press-fit, solder-fit and so on. They'll have something you can use I'm positive of it. 

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tterev3 wrote:
started the main & daughter boards. got the outlines set and basic component arrangement established. here’s the current challenge: locating the 4 pins that pass from main up to daughter while avoiding impeding on the space for battery contacts and the shelf (exposed case material, must be unmasked copper) regions.

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Woohoo, finally got the shipping notice for mine (added stuff holding the shipment up). Should be here Wednesday. Think I’ll go ahead and do a review on mine before I tear it apart.

 

Always remember SPC Joey Riley, KIA 11/24/14.

tterev3
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Got everything fully routed. The daughter board looks like it’s ready to order. The main board has everything connected, but I still don’t like the look of it… may need more work

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work of art!

Love the sweeping turns of the traces on the right…beautiful!

Did you make a round polygon pour?

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“Ratsnest: nothing to do”. Beautiful, I bet it even passes DRC huh.

I really like all the extra copper pour on the daughter board. I’ve started doing that too, I like the finished look better plus the extra heat sinking it provides.

 

Always remember SPC Joey Riley, KIA 11/24/14.

tterev3
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WarHawk-AVG wrote:
Did you make a round polygon pour?

The trick is to do a big polygon around everything that’s not any particular shape. Then when you have a circular board edge, the pour will automatically isolate from it by whatever distance you set in DRC and it matches the shape exactly

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tterev3 wrote:
WarHawk-AVG wrote:
Did you make a round polygon pour?

The trick is to do a big polygon around everything that’s not any particular shape. Then when you have a circular board edge, the pour will automatically isolate from it by whatever distance you set in DRC and it matches the shape exactly


Will it isolate itself inside the milling layer?

Sweet…great to know..thanks a ton tterev3

tterev3
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main board is almost there:

tterev3
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finally done, and ordered!

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Have fun putting that together!

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Wow nice.

My F30R got here today!

 

Always remember SPC Joey Riley, KIA 11/24/14.

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tterev3 wrote:
finally done, and ordered!

MRsDNF
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Nice. With a comment from Matt like he did this must be a challenge. To me it would be an impossibility.

My current and or voltage measurements are only relevent to anything that I measure.

Budget light hobby proudly sponsored by my Mastercard and unknowingly paid for by a hard working wife. 

djozz said "it came with chinese lettering that is chinese to me".

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

saypat
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checkbook is ready, not sure there is enough in it though :_(

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