JoshK's Machine Made 'Studio Light' for the 7th Annual BLF/OL Contest (Beamshots!)

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Joshk
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JoshK's Machine Made 'Studio Light' for the 7th Annual BLF/OL Contest (Beamshots!)

My Goals
1) Build something that I need and will use, not a shelf queen. It’s not a win if all it does is look pretty for the camera, then go to storage.
2) Outperform expectations on 3D prints. The internet is filled with pics of 3D prints that look like they belong in a dollar store. This won’t be one. I promise.
3) Inspire others that only have a 3D Printer to join in next year’s Old Lumens competition! That’s the spirit of this competition, to get people involved and building.
4) Follow the basics of good design. Mind the weight, cost, and labor needed. I might want more than one. Maybe BLF members will want a parts kit? Like #3 said, I want to inspire.
,
,
The Power
For the platform, I am using this battery pack I made already. It contains (10) Samsung 30Q batteries! That’s what? 20v * 30A = 600watt. Yea, that will do nicely. Big Smile

,
,
The Dock
Let’s get connected in style! I am designing a dock that can slide on and latch just like a Dewalt tool!

,
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The Terminals
Now the problem solving begins. These holes are meant to capture and hold on to a standard spade connector. I may add 2 more in the “FlexVolt” jumper positions before printing. But it’s about time to print something and see how it fits.

,
,
Checkpoint
The CAD model is in no way nearing completion, but I need to check fit and function before going too far. Making changes to the foundation of the design at a later date can totally break the models. Ask me how I know.
It fits a bit loose, so I will be adjusting some measurements by feel. But overall it’s quite good. Onward!

,
,
World First!
I decided I wanted individual cell monitoring to alarm me if one cell in the pack reached empty before the rest. And I have some small pins that are perfect. To my knowledge, no hobbyist has ever made a fully functional 8 pin Dewalt-compatible dock. Until now. It wasn’t easy cramming all that geometry into such a tight space while leaving room for the .4mm print nozzle on the printer. But I did. Booya!

,
,
What is that?
That’s goals being met. The inside-out design is great. It’s light weight, has excellent passive cooling, and takes minimum print time and labor to assemble. There will be a “headlight” mounted to the left and right side. You may have seen or heard in my other threads that what I call a headlight is a ring I designed that mounts a CPU cooler to a tripod. In this case, 2 will thread on to the sides.


,
,
ooh, shiny!
Here are the headlight rings! The sanded/painted one sure looks more impressive than the unpainted one! This paint job meets goal #2. To “Outperform expectations on 3D prints”. It doesn’t look cheap now, does it?

,
,
Ready for takeoff
After a break I am back on the project today. I will start wiring things up. This metallic paint sure is hard to photograph. Notice how different it looks in this pic compared to the last one on a sunny day.

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Putting it all together
First, a headlight. The CPU Cooler just press fits in. Then I pull up the two unused wires and clip them. Then tuck them back in.

,
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Then I solder 8” wires to each pad of the COB. Then apply thermal paste to the heatsink. Then screw the COB on.

,
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Then I slide a LM7812 voltage regulator into place on the main dock. It fits in upside-down so any heat transfers upwards into the aluminum plate on the bottom of the boost converter. The location also hides and protects its wires. Quite a clever feature if I do say so myself. It worked excellent. Smile I also put the power switch and headlight bolts in place.

,
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Then I hung the headlights and run their power wires to the 12v output on the regulator. I attached a red and black wire to the other two pins to feed it battery voltage. And the fan ground wires will go to the battery terminal. I had to extend the darn COB wires because I made them too short and it’s a pain to re-solder the other end. Then I was able to route them under the boost-converter’s area.

,
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I soldered two red wires to the power switch.

,
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Then I just wired it up to the battery terminals. The boost board only has 2 wires coming in and 2 wires going out. The wires from the voltage regulator just needed battery voltage. And the other two blacks are the ground wires from the fans.

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Then I turned on the power and it was almost flawless. Apparently I had hooked the voltage regulator to un-switched power, so the fans run all the time. That was a super quick fix. As you can see the cell monitor is correctly cycling through the voltages on each cell.

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Beamshots!
It’s been rainy lately, but I did beamshots in the light rain anyway Big Smile
It’s pitch black in my backyard with the light off. And like daytime with it on Big Smile


Is this a cool shot or what? Big Smile



The handle is balanced perfect so I can carry it with one finger Smile


Edited by: Joshk on 12/10/2019 - 20:01
Joshk
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Reserved

Agro
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Nice warmup. Smile

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Looking forward to this build Thumbs Up

The Miller
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Cool josh, make it wind powered to be able to add you own made windmill to the thing and be even more impressive Smile

Joshk
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The Miller wrote:
Cool josh, make it wind powered to be able to add you own made windmill to the thing and be even more impressive Smile

Do you mean like this:

I 3D printed that too a few years ago. It works, and it would charge my pack. Big Smile

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I remembered right after I posted that it wasn’t a coincidence, The Miller already knew I had designed and printed a wind turbine in the past Big Smile
-PS, if you didn’t see it in the other thread, Welcome back! I had asked about you. Nobody was sure what you were up to.

Everyone – I updated the OP with a dock design!

pinkpanda3310
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Cool, when I got into the hobby I wanted to make a monster that ran on tool battery packs. Never did it though. So looking forward to your build.

 

DavidEF
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Oh, this is gonna be cool! Can’t wait to see how it ends up! Good luck!

The Cycle of Goodness: “No one prospers without rendering benefit to others”
- The YKK Philosophy

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Looking forward to watching this build. Great starting point

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Wow. I could make a lot of magic smoke with that battery pack. Looking forward to seeing your creation evolve. Smile

 

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

                      "My man mousehole needs one too"

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.

 

G0OSE
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Also looking forward to seeing your entry Smile glad you are entering!

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Thanks for the encouragement everyone Smile

Joshk
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Added some goals

My Goals
1) Build something that I need and will use, not a shelf queen. It’s not a win if all it does is look pretty for the camera, then go to storage.
2) Outperform expectations on 3D prints. The internet is filled with pics of 3D prints that look like they belong in a dollar store. This won’t be one. I promise.
3) Inspire others that only have a 3D Printer to join in next year’s Old Lumens competition! That’s the spirit of this competition, to get people involved and building.
4) Follow the basics of good design. Mind the weight, cost, and labor needed. I might want more than one. Maybe BLF members will want a parts kit? Like #3 said, I want to inspire.

MtnDon
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Cool! Thumbs Up

BLF Member Map Add your name and location.

MRsDNF
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Way to go Josh. Beer

 

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

                      "My man mousehole needs one too"

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.

 

Joshk
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Checkpoint
The CAD model is in no way nearing completion, but I need to check fit and function before going too far. Making changes to the foundation of the design at a later date can totally break the models. Ask me how I know.
It fits a bit loose, so I will be adjusting some measurements by feel. But overall it’s quite good. Onward!

Barkuti
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Joshk wrote:

For the platform, I am using this battery pack I made already. It contains (10) Samsung 30Q batteries! That’s what? 20v * 30A = 600watt. …

The average voltage coming out of a 30Q cell when discharged at 15A is more like ≈3.35V, this means the average continuous power delivery rating from such pack is ≈500W, no more.

Interesting to see such an odd project, I like oddities. Smile 

grin
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Good work i like it a lot. 20 in parallel could give you 10-12kw. Nearly enough to fire my brewery until the genset can take over.

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It is a bad-ass little pack Cool
Do you have a pic of your brewery somewhere? It sounds interesting.

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World First!
I decided I wanted individual cell monitoring to alarm me if one cell in the pack reached empty before the rest. And I have some small pins that are perfect. To my knowledge, no hobbyist has ever made a fully functional 8 pin Dewalt-compatible dock. Until now. It wasn’t easy cramming all that geometry into such a tight space while leaving room for the .4mm print nozzle on the printer. But I did. Booya!

grin
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Im at work at the moment. I was out of control last year before the police pulled me up. So i stopped drinking and the brewery went on the backburner it wasnt quite legal so i deleted most of the evidence.140L mash tun, 170L kettle, 100L fermenter, 150L bright tank, then i had the yeast lab, it is all stainless steel and glass. I will have a look for photos when i get home.
I dont want to take your thread of topic. This is part of the yeast lab and it is only for sterilization of wort nothing else like some people imagine. The only one i didnt delete

Next year i will buy a shouse (shed house) and the brewery will be built into the kitchen with fixed lines running to the fermenters and bar

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That sounds huge! Don’t get in trouble posting pics.

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That’s some pro grade stuff there Grin Smile

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Barkuti wrote:

Joshk wrote:

For the platform, I am using this battery pack I made already. It contains (10) Samsung 30Q batteries! That’s what? 20v * 30A = 600watt. …


The average voltage coming out of a 30Q cell when discharged at 15A is more like ≈3.35V, this means the average continuous power delivery rating from such pack is ≈500W, no more.


Interesting to see such an odd project, I like oddities. Smile 

It was just a quick sanity check. I am planning a 200w build.

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So, to clarify… This is compatible with the 20V MAX line of battery tools?

The Cycle of Goodness: “No one prospers without rendering benefit to others”
- The YKK Philosophy

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“individual cell monitoring” I’ll be interested in seeing this Glasses

 

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DavidEF wrote:
So, to clarify… This is compatible with the 20V MAX line of battery tools?

I own genuine Dewalt 20v MAX batteries and genuine Dewalt FlexVolt batteries, and it fits them all perfect.

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If anyone has trouble seeing images, please let me know. PM is good too. I’m doing it the most convenient way possible, but there are other options.

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What is that?
That’s goals being met. The inside-out design is great. It’s light weight, has excellent passive cooling, and takes minimum print time and labor to assemble. There will be a “headlight” mounted to the left and right side. You may have seen or heard in my other threads that what I call a headlight is a ring I designed that mounts a CPU cooler to a tripod. In this case, 2 will thread on to the sides.

Joshk
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ooh, shiny!
Here are the headlight rings! The sanded/painted one sure looks more impressive than the unpainted one! This paint job meets goal #2. To “Outperform expectations on 3D prints”. It doesn’t look cheap now, does it?

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