Custom High power LED light bar

350 posts / 0 new
Last post

Pages

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan
Custom High power LED light bar

Hey guys, I just wanted to post a quick pic of the preliminary light bar design. First and foremost, the optics are TIR lenses by Gaggione, the two large ones are the 67mm LLC56N, 12 degree spot with a XHP-70, or 9 degrees with a XHP-50. The 4 smaller ones are an elliptical 45mm LLC49E, 40 degree wide beam and only 14 degrees vertical beam, it’s a wide flat flood, which is what you want in an automotive light.

The floods HAVE to be the XHP-50 as the 70’s are too big for them. But the spots can take 70’s, and I will go with that as they would both have the same lux (~90,000 candela), only the 70 has a larger 12 degree beam over the 50, so I figured why not.

The heatsink on the back is 350mm x 100mm x 48mm, it has 33 fins (3mm to 1.5mm tapered fins) with a thicker 4mm straight fin on each end. Made by Conrad Heatsinks in Australia.

The LED housing is 15mm wall thickness, there is no point in making it thinner as it has to be machined from a solid block of aluminum anyways. And since this is custom, it would only cost more to do more machining. There is an o-ring trench top and bottom, against the heatsink and against the lense… the front bezel pushes down on the lense, onto the o-ring trench.

The LEDs will be driven at 100%, so 18,000 Lumens combined. They will be the top binned chips so expect pretty close to that number. The drivers will have several modes, so no need to blind people 2 miles away if you don’t need to. Smile

The spots and floods will have individual controls as well, so if you don’t need spots, turn them off, and visa-versa.

Let me know what you think.

 photo LED light bar assembly_zpsucptmodr.png

 photo LED housing pic_zps8l3aefdn.png

Edited by: zpinch on 02/22/2016 - 19:08
WillyD
Offline
Last seen: 6 hours 9 min ago
Joined: 10/10/2012 - 15:55
Posts: 645
Location: Ohio

Yikes, that looks like a lot of $$$. Pretty cool, though. Was hoping this might be something budget I could incorporate on my zero-turn, but I’ll pass :-/
You mentioned automotive light…what are you planning to put this on?

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

With a couple people I have in on it, it looks like around $300 – 350. But you couldn’t buy a more compact, more powerful light bar that is built as good as this. Smile If that puts it into perspective. I found that you can’t make a cheap light bar, if built properly, so I said what the hell, spend a bit more and get alot more…

I will put it on my CRV of course! Smile Saskatchewan roads with lot’s of wildlife running around needs some light I think!

Cheers.

Hoop
Hoop's picture
Offline
Last seen: 2 weeks 1 day ago
Joined: 12/20/2012 - 05:33
Posts: 746
Location: Spokane, WA

I think it’s real cool to see those Gaggione optics put to use. Also I like the design. The heatsink portion being made from an off the shelf extruded profile is nice for cost reduction. The protective lens looks easy enough to replace by the user. Of course if your chosen led’s don’t work out as intended, as far as the beam goes, you can always try others. Same goes for the optics. Beer It could be made cheap(er) in bulk if the machined aluminum portion were an extrusion. Then it would only need tapped holes and the O-ring Groove machined. Well, mostly.

WhitedragonBC
WhitedragonBC's picture
Offline
Last seen: 2 months 1 week ago
Joined: 05/17/2014 - 00:42
Posts: 164
Location: California

That’d be pretty easy on the eyes with some nice warm tints like http://www.mtnelectronics.com/index.php?route=product/product&path=60_11... or http://www.mtnelectronics.com/index.php?route=product/product&path=60_11... to match the headlight tint.

mapache
mapache's picture
Offline
Last seen: 55 min 18 sec ago
Joined: 08/10/2015 - 09:34
Posts: 1079
Location: Vic, Aus

That looks really good, would be perfect for the front of my car. Will be keeping an eye on this thread even if it is far out of my price range. Vibration resistance and water ingress will probably be the biggest issues. If it turns out as good as it looks from the specs $300-350 seems like a reasonable price compared to other high end lightbars.

I wouldn’t go too warm with the tint. It’s personal preference but I like aux lighting to be as close as possible to headlight tint.

pilotdog68
pilotdog68's picture
Offline
Last seen: 5 days 17 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6346
Location: Held against my will in IOWA, USA

I like the design, it’s just about what I was wanting to build myself. I’d be more interested in just buying the shell+optics to fill with my own driver and emitter choices.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan
Hoop wrote:
I think it’s real cool to see those Gaggione optics put to use. Also I like the design. The heatsink portion being made from an off the shelf extruded profile is nice for cost reduction. The protective lens looks easy enough to replace by the user. Of course if your chosen led’s don’t work out as intended, as far as the beam goes, you can always try others. Same goes for the optics. Beer It could be made cheap(er) in bulk if the machined aluminum portion were an extrusion. Then it would only need tapped holes and the O-ring Groove machined. Well, mostly.

Yeah, I like these optics too, but the only thing I am wondering if they are missing, is beam ‘field’, which there is a lack of with TIRs, it puts the light where you want it… do we need a beam field, I don’t know. I will find out when the LEDs come in. Yes, everything will be changeable, including the optics, but I am going to do alot of playing around with them on their own before I am sure they are going to be used.

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan
WhitedragonBC wrote:
That’d be pretty good with some nice warm tints like http://www.mtnelectronics.com/index.php?route=product/product&path=60_11... or http://www.mtnelectronics.com/index.php?route=product/product&path=60_11...

5000k LEDs is what I am getting, it is the optimal color temp for visibility and eye strain/fatigue. It is just a touch warmer than direct sunlight.

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

mapache wrote:
That looks really good, would be perfect for the front of my car. Will be keeping an eye on this thread even if it is far out of my price range. Vibration resistance and water ingress will probably be the biggest issues. If it turns out as good as it looks from the specs $300-350 seems like a reasonable price compared to other high end lightbars.

I wouldn’t go too warm with the tint. It’s personal preference but I like aux lighting to be as close as possible to headlight tint.

I think it will look good too, thanks. Vibration is my only thing to workout, as far as the optics go, securing them is one of the only things I am still working out, but I will figure it out when the LEDs come in. The LLC56N is light for being a solid piece of plastic, as it’s PMMA, but relatively heavy for a lense of it’s size, compared to a reflector I think?

Yes, you compare it to a standard 50” amazon.com light bar, it would probably outperform it, in light quality (color temp), as well as beam profiles, so puts the light where you need it, and thus probably providing more light. Those light bars only run at 60% LED power, they rate the light bars based on the max LED wattage/lumen rating.

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

If anyone is interested in possibly going in on this project, let me know. The more the better.

wight
Offline
Last seen: 3 weeks 3 days ago
Joined: 11/27/2013 - 16:40
Posts: 4957
Location: Virginia, USA

You have a driver lined up?

Still taking a break. Smile
list of my drivers & variants (A17DD, FET+1 stuff, WIP stuff, etc)

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

I was thinking THESE, 2 drivers to run 4 xhp-50s, and one for each 70.

Or a couple of Taskled drivers, but the Taskled doesn’t have direct switch activated modes, only click modes, which you don’t want on an automotive light.

wight
Offline
Last seen: 3 weeks 3 days ago
Joined: 11/27/2013 - 16:40
Posts: 4957
Location: Virginia, USA

Too bad that this manufacturer does not have a nice boost circuit (or at least the eBay seller doesn’t seem to carry one). OTOH I’m pretty sure that I don’t need modes in that application anyway, so TaskLED would be fine.

Still taking a break. Smile
list of my drivers & variants (A17DD, FET+1 stuff, WIP stuff, etc)

MRsDNF
MRsDNF's picture
Offline
Last seen: 46 min 47 sec ago
Joined: 12/22/2011 - 21:18
Posts: 11478
Location: A light beam away from the missus in the land of Aus.

Would the Taskled handle the so called voltage spikes from the charge system on a car?
What area are you from zpinch.

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.

 

Hoop
Hoop's picture
Offline
Last seen: 2 weeks 1 day ago
Joined: 12/20/2012 - 05:33
Posts: 746
Location: Spokane, WA

It’s worth looking at DIWdiver’s linear automotive drivers. They can be customized a bit. 1, 2, 3.

foolioGrimz
foolioGrimz's picture
Offline
Last seen: 1 year 5 months ago
Joined: 10/09/2015 - 05:01
Posts: 209
Location: Texas

Sweeeeet! your design looks better than mine for sure. $350 would be a steal for that unit. Would that heatsink be able to handle that much XHP? what kind of wattage are you planning?

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

Wight, what do you need a boost circuit for, do you think that maybe the 12v system wouldn’t have enough voltage when the alternator isn’t turning? For 100% power that is.

MRsDNF, I don’t know if it could handle the voltage spikes, but I don’t know much about the TaskLED drivers, nor do I about the other drivers that I posted above… I have a 3 amp and a 2.4 amp unit from them coming in the mail, however. To test. I am from Saskatoon, SK, Canada. eh

Hoop. I checked out those drivers, they look pretty good, I might snatch one up to test.

foolio, thanks, glad you guys like it. $350 would be a nice price point, I would like to keep it under $300 though ideally. I am almost certain the heatsink can handle 140watts of heat, it’s pretty hefty (1.6 kg/3.5 lbs), and is rating at 0.28C/W, that is 40 degree rise at full power. I am not sure if that is rated for a small amount of airflow across the fins, or merely natural convection, but either way, that is pretty good.

The front lense will be an AR polycarbonate 0.25 Inch sheet. That is abrasion resistant, not anti-reflective, if you are wondering.

Jinx
Jinx's picture
Offline
Last seen: 1 day 10 hours ago
Joined: 10/16/2011 - 11:35
Posts: 1044
Location: England

Interesting, I’d be keen but I’ve seen these type bars come and go on here, none very successful so far…

dude5
dude5's picture
Offline
Last seen: 1 year 6 months ago
Joined: 12/30/2015 - 09:16
Posts: 49
Location: Houston

$350 is out of my price range… I have really wanted to build one like this too, but dont have the resources for the housing. If it was closer to 200-250 I would be in for sure.

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

$350 is at the top of my price range… I would like to make it for 200 really, if I take out a couple LEDs, use a smaller elliptical optic and thus a shorter housing will help.

I really find using XHP 50s and 70s are the way to go, for a DIYer, you can’t beat the price/watt, when you factor optic costs into the equation.

will34
will34's picture
Offline
Last seen: 3 weeks 6 days ago
Joined: 12/18/2012 - 00:12
Posts: 3193

Interesting project… I used taskled drivers before in maglite mods so I think this could be useful:

For the 4 XHP50s in the middle I would say the Taskled HBFlex would be optimal for the application, its a boost driver with 7-24V input and drives up to 48V at 3A. With proper heat sinking it can run for as long as you wish.

For the two outer XHP70s.. H6Flex comes to mind (buck driver < 25V in > 7V out at 6.6A) but the output might be limited due to the small input-output voltage difference when the Vf raises. A DC-DC step up converter can be used here to supply 24V to the driver, also decreasing the required current draw required to supply full power to both leds.

http://www.taskled.com/h6flex.shtml

You could also use 2x H6Flex to power the middle and outer LEDs separately, each with it’s own DC-DC 12v-24v boost circuit which are pretty cheap: http://www.ebay.com/itm/DC12V-Step-Up-to-24V-240W-10A-Car-Power-Converte...

But this is a very expensive setup, that’s almost $100 in drivers alone.

mapache
mapache's picture
Offline
Last seen: 55 min 18 sec ago
Joined: 08/10/2015 - 09:34
Posts: 1079
Location: Vic, Aus

Are voltage spikes still an issue in modern vehicles? I was under the impression that providing you use good quality accessories and don’t do anything like disconnect the battery with the engine running they were quite uncommon unless you have a major component failure, in which case one would worry more about the various ECUs than a lightbar.

MRsDNF
MRsDNF's picture
Offline
Last seen: 46 min 47 sec ago
Joined: 12/22/2011 - 21:18
Posts: 11478
Location: A light beam away from the missus in the land of Aus.

mapache wrote:
Are voltage spikes still an issue in modern vehicles? I was under the impression that providing you use good quality accessories and don’t do anything like disconnect the battery with the engine running they were quite uncommon unless you have a major component failure, in which case one would worry more about the various ECUs than a lightbar.

I dont know but it comes up often when this topic arises.

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.

 

mapache
mapache's picture
Offline
Last seen: 55 min 18 sec ago
Joined: 08/10/2015 - 09:34
Posts: 1079
Location: Vic, Aus
MRsDNF wrote:
mapache wrote:
Are voltage spikes still an issue in modern vehicles? I was under the impression that providing you use good quality accessories and don’t do anything like disconnect the battery with the engine running they were quite uncommon unless you have a major component failure, in which case one would worry more about the various ECUs than a lightbar.
I dont know but it comes up often when this topic arises.

Wait, were you talking about normal voltage fluctuations of ~15v or +100v spikes?

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

You know, the more I think about the TaskLED drivers, the more I don’t want to use them, at least for now. The price for just the drivers is ridiculous, more than the LEDs themselves. I am gonna go with the Russian sourced units, I like how they set them up for modes, good price too. Sure, it would be very nice to have thermal shutdown safety built into the driver, but I can live without it for now. Everything will be interchangeable, so I can see in the future I will upgrade that part.

Voltage spikes shouldn’t be an issue, no. If you are worried, there are ways to stabilize the power, for both the electrical noise and voltage fluctuations.

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

Here are the optics that have come, the smaller elliptical TIR is a Carlco 30mm. The large lense is the 67mm Gaggione LLC56N, the one next to it is the 45mm LLC49E. The headlamp is an Armytek Wizard Pro V2, for size reference. Can’t wait to light those babies up with some xhp monsters.

 photo 20160215_214513_zpsoelhn3nq.jpg

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

I have purchased 2 of those drivers from Russia 2 days ago, one 3 amp model with 4 switch modes, and a 2.4 amp model with 4 modes as well. It might be a few weeks before I get them so hang in there. LEDs I was expecting this week, nothing yet.

Aardvark Spleen
Aardvark Spleen's picture
Offline
Last seen: 1 week 4 days ago
Joined: 10/25/2015 - 16:22
Posts: 63
Location: Chehalis, WA USA
zpinch wrote:
If anyone is interested in possibly going in on this project, let me know. The more the better.

What’s this mean? I might be interested.

zpinch
zpinch's picture
Offline
Last seen: 1 month 1 week ago
Joined: 01/16/2016 - 11:21
Posts: 192
Location: Saskatchewan

Well, the more people who would buy at the same time, the cheaper the light bar will be, down to a point of diminishing savings… I think after about 5 or 6 light bars made the savings difference would be negligible. The CNC machining of the housing/case is the part that will make it cheaper with volume, this is what I am referring to. Also, I suppose the shipping costs for all the others part to be ordered will be reduced with volume as well.

Here is another pic, I made the elliptical lense, well, elliptical (horizontal lines on the lense face)… only it is 90 degrees the wrong tilt, I tried turning it in CAD, it allowed me to do it, but it just didn’t visually change. Not sure about that?

 photo LED light bar assembly 3_zpsza12xbrd.png

southland
southland's picture
Online
Last seen: 14 min 14 sec ago
Joined: 11/04/2012 - 07:15
Posts: 2813
Location: Georgia, USA

Might be interested, are the parts being machined in Canada?

Pages