My new headlamp (driver challenge...)

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Jerommel
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My new headlamp (driver challenge...)

Hi guys,

I have found a new headlamp for a decent price:

https://www.aliexpress.com/item/T6-Rechargeable-Headlights/32672336495.html
https://www.aliexpress.com/store/product/Severe-Cold-6000lm-CREE-XML-L2-...
Prices may vary, i paid around $ 16

Brand: Shuolide
Rechargeable 18650 headlamp with headband and the light in the middle.
FAKE XM-L2 on a little over 1000mA. nope, see edit..
2 modes: medium and high, ramping feature (unfortunately without memory) on both modes, double click for strobe.
UI is medium > high > off. I can live with that.
No visible PWM Thumbs Up
No PWM at all apparently. Thumbs UpThumbs Up (checked visually with a spinning fan)

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EDIT:

Sooo…. it turns out the thing has no current regulation…
I didn’t expect this at all, but on a fresh battery the current is much higher (like TWICE as much) than on a partially discharged one…
So i was too soon with my enthusiasm and i hope i didn’t make people buy this light to be honest…
On the highest mode ramped up to maximum i just measured around 2 Amperes, which is more than i need, beyond the specs of the LEDs and it gets quite hot too.

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I modded it, but it’s not finished yet:

I put in 8x OSRAM DURIS E5 LED 4000K 95CRI 5730 size 0,5 Watt.
Lovely LEDs with virtually no tint shift.
So it’s a “mule” with no hotspot, total flood.
Very pleasant for close up work like modding flashlights Big Smile

Had to change the spring, because the stock one was very short, barely making contact with the battery.
Copper shim with taller spring glued inside the end cap.

Micro USB rechargeable.
I also put on a different headband from an older headlamp i never used as a headlamp.
The headband it comes with is nice quality and black, but doesn’t have the band that goes over your head.
It was okay, but this is better (for me).

Hmmm… Very green button, want to put in a black one but didn’t get the end unscrewed yet.

This light is approximately 20 grams lighter in weight than my previous one.
This one weighs 143.7 grams with Panasonic 3400mAh and head band.
Sure, the Skilhunt H03 is lighter, but not floody enough and i don’t like the light isn’t in the middle.

It will eventually weigh a couple of grams more, because i’ll put in a diffuse lens of some sorts.

Anyway, i thought i’d share this with you because it’s a user friendly and fairly easily mod-able headlamp.
The medium mode is just the right brightness, i estimate it’s 1.25 Watt or maybe a little more.

EDIT: So this highly depends on the battery voltage… Tired
read later posts if you’re interested in the driver challenge..

Looking for:

5” parabolic reflector (for recoil light)

Edited by: Jerommel on 05/18/2017 - 20:56
AgentSteel
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So you don’t need to change the driver, no risk to fry the new led? (sorry the question will sound stupid but I’m a total noob when it comes to modding)

Work. Consume. Sleep.

Jerommel
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AgentSteel wrote:
So you don’t need to change the driver, no risk to fry the new led? (sorry the question will sound stupid but I’m a total noob when it comes to modding)
A stupid question is a question you don’t ask. Wink

EDIT:
Yeah, like me not asking if this driver has current regulation… Facepalm
So it turns out i do need to change the driver because it pushed a whopping 2+ Amperes through those poor little LEDs with a fully charged battery…

Looking for:

5” parabolic reflector (for recoil light)

AgentSteel
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Thanks Thumbs Up

Work. Consume. Sleep.

Turningbluechips
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Neat mod. I envy your soldering skills.

CRX
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Nice idea Thumbs Up

MRsDNF
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Well done. The extremes some go to. Thumbs Up

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.

 

Ronin42
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very nice (in my best borat voice)

(“It’s good that most people can’t remember their previous lives. Otherwise
things would be a lot more complicated than they already are.”
Ajaan Lee Dhammadharo)

L4M4
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what type of pcb are you using there?
I have plenty (2000?) of 5730 LEDs and would love to do something with them Big Smile

dekozn
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I’d like some explenation on the pcb also. How did you fix it, cause on the pic it looks like + and – are shorted with solder ? I’m guessing the mid stroke of copper on pcb is – and the 2 outsides are +.

Cool mod tough. How do the COB LEDs compare to cree/nichia led in a mule setup?

Jerommel
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dekozn wrote:
I’d like some explenation on the pcb also.
The one with 6 of these LEDs on them was a XM-L board, the one with 8 (in the light) and the bare one were XP boards.
Some of them have that long centre pad (you say “mid stroke”), which is ideal for this purpose.
I just sanded off the masking paint.
Quote:
How did you fix it, cause on the pic it looks like + and – are shorted with solder ? I’m guessing the mid stroke of copper on pcb is – and the 2 outsides are +.
Thumbs Up Exactly.
Quote:

Cool mod tough. How do the COB LEDs compare to cree/nichia led in a mule setup?

They have practically no tint shift, so everything is the same tint, both in front of you and to the sides.
My other headlamp (which is starting to wear down a bit) has a single 219C and does have a little more yellow on the outer perimeter, even with diffusing optics.

Looking for:

5” parabolic reflector (for recoil light)

EasyB
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Nice mod.

It looks like the plus and minus are shorted, but they must not be?

Jerommel
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L4M4 wrote:
what type of pcb are you using there?
I have plenty (2000?) of 5730 LEDs and would love to do something with them Big Smile
2000 ?! Big Smile
That’s 1 Kilowatt of LED power…. Ughh
I bought these some time ago:
http://www.ebay.com/itm/100-pcs-OSRAM-DURIS-E5-LED-4000K-CRI-95-HIGH-QUA...
I really like them.
That shop has many more high CRI Osram LEDs by te way.

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5” parabolic reflector (for recoil light)

Jerommel
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EasyB wrote:
Nice mod.

It looks like the plus and minus are shorted, but they must not be?


The centre pad is the minus. Wink

Looking for:

5” parabolic reflector (for recoil light)

EasyB
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Jerommel wrote:
EasyB wrote:
Nice mod.

It looks like the plus and minus are shorted, but they must not be?


The centre pad is the minus. Wink

Right, but it looks like you have solder going across all three pads.

Also, how is the UI? Edit: I saw you explained it some in the OP.

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EasyB wrote:
Jerommel wrote:
EasyB wrote:
Nice mod.

It looks like the plus and minus are shorted, but they must not be?


The centre pad is the minus. Wink

Right, but it looks like you have solder going across all three pads.
Yeah, it looks like it, but it’s not so.
There’s just very little space left when you put 8 of them on it.
In the picture with 6 on it you can see better.
So i soldered a jumper over the outer pads, where the red wire is soldered on to.
Quote:

Also, how is the UI?
low, high, off. e-switch.
Long press for ramping. First long press increases, second long press decreases output, would be better if it decreased the first long press.
No ramping memory.
double click for strobe.
Not perfect, but no PWM. Thumbs Up

(edit: Yeah i did explain in the OP Smile )

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5” parabolic reflector (for recoil light)

Jerommel
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MRsDNF wrote:
Well done. The extremes some go to. Thumbs Up
Well, i use a headlamp daily.
Together with my reading glasses it makes me see very well what i’m doing.
With external lighting there’s always shadows cast on the things i’m working on / with.

I’ve found a lens that fits (after some filing) too, to finish it off, but haven’t found a proper way to hold it in place yet.

Looking for:

5” parabolic reflector (for recoil light)

Lightbringer
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Jerommel wrote:
Hmmm… Very green button, want to put in a black one but didn’t get the end unscrewed yet.

Backlit?

My RJ02 glows red when charging and when in magic mode (wave on, wave off), and green when finished charging.

Maybe yours glows green after charging?

09 F9 11 02 9D 74 E3 5B D8 41 56 C5 63 56 88 C0

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Very nice headlight build. I also love hi cri mule 18650 headlights. I’ve always used nichias. I’m not familiar with the emitters your using. They are cheap enough to experiment with some. Thanks for bringing these to my attention. What would you guesstimate the lumens on high is?

hank
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How good is the charger? Channel your inner HKJ and comment, does it stop charging when the cell is full, no ongoing trickle?

Jerommel
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hank wrote:
How good is the charger? Channel your inner HKJ and comment, does it stop charging when the cell is full, no ongoing trickle?
I’m not sure, but the little LED goes green when it’s fully charged.
Good question though.
I’ll have to (finally !) replace the fuse in my DMM and test this.

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5” parabolic reflector (for recoil light)

Jerommel
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electricjelly wrote:
Very nice headlight build. I also love hi cri mule 18650 headlights. I’ve always used nichias. I’m not familiar with the emitters your using. They are cheap enough to experiment with some. Thanks for bringing these to my attention. What would you guesstimate the lumens on high is?
I really don’t know that..
Those LEDs are rated 0.5 Watts and 47 Lumen, but maybe it’s lower because these are high CRI.
But then again i’m using them on lower power than 0.5 Watts each, so they probably work a little more efficient, especially on the low mode (which seems to be without PWM).

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5” parabolic reflector (for recoil light)

Jerommel
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Lightbringer wrote:
Jerommel wrote:
Hmmm… Very green button, want to put in a black one but didn’t get the end unscrewed yet.

Backlit?

No, just very green.. Smile
Just your average old school green GITD switch boot.

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5” parabolic reflector (for recoil light)

Jerommel
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OP updated, not good news…
No current regulation, so the driver sucks…
I did finish the thing by putting in a lens, maybe i’ll show you later.

Maybe i can replace the driver, didn’t get that part open yet..

EDIT:
I got it open.
It seems the driver and charging circuit are not on the same PCB so there’s hope.. Silly
(No pics yet, camera battery is charging)

Looking for:

5” parabolic reflector (for recoil light)

dekozn
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bummer dude but still I learned a new rick with the pcb. Hope u can change out the driver (and if u can, well u know u will have a decent light)

Jerommel
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dekozn wrote:
bummer dude but still I learned a new rick with the pcb. Hope u can change out the driver (and if u can, well u know u will have a decent light)
I’m not giving up (yet…).

First the good news Facepalm :

I found a useless double convex PMMA (i think) lens that i made to fit in the opening.
I sanded one side flat in one direction so that it spreads the light a little horizontally.
I thought i’d try that and it works rather well. Smile
Yeah, i painted the bare aluminum circumference black again too.
It got damaged when i took out the original LED board so i sanded it.
Looks neat huh?

And then the bad news… Party

I enhanced some things in the picture.

On the right, the charging PCB.
I’ll just leave that as is.
Maybe someone can tell what kind of circuit it is and if it shuts off when fully charged or if it ‘floats’ on 4.2 Volts.

On the left, the driver board, the e-switch and some peripheral parts (2 Rs and 1 C) are on the other side.
So basically the unmarked IC does the UI and regulates the 2 tiny “00A8C” FETs.
Their output goes to 3 x R680 in parallel (0.23 Ohm) to the LEDs.
So there’s no current regulation….
….so i took the FETs and the resistors off.
I want to replace those parts with those 3 chips there, those are CN5611 current regulators, like variable 7135s.

Bought a bunch some time ago, and i think i can drive them with the IC output (connect to pin 4 “ISET” via a yet to be determined resistor), instead of the FETs.
They can do 30 to 800 mA each, but there’s a considerable voltage drop above 400 mA, so i plan to use 3 of them in parallel, and 1200 mA total would be quite enough.
The CN5611 has a Voltage drop of around 0.2 Volts at 400mA.

The challenge is getting them on the board with some sort of thermal path and working within the desired range.
It would be 90 to 1200 mA when all works out well.
1200mA is not much, but it’s enough for its purposes and otherwise it will get hot and it’s around the maximum rated power of the Osram LEDs.

Looking for:

5” parabolic reflector (for recoil light)

electricjelly
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I love the new look you came up with.

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 The charge circuit is a AP5056 and has the capabilities to indicate " charge" and "termination charge " states Find below a data sheet link :

   www.led-ics.com - AP5056_datasheet.pdf

 You don't stop amazing me with your imagination !... So many gifted people , forced to do something else to make a living...

Adrian

Jerommel
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Hey, thanks Adrian.
So at least the charging board is okay.. Big Smile

Looking for:

5” parabolic reflector (for recoil light)