Project Excalibur - Next Generation LED Thrower (many pics) - UPDATE 2018-01-24

Thanks for the detailed answers.

Isn’t the large SST90 amp hungry at 3-4V? Big die?

Dang I hope you’ll be able to compare your monster to the GT when it is done, they are pretty close on a lot of sizes.

Yes the Luminus SST-90, CBT-90 and SBT-90 are 3V LEDs which can take high current (up to 18A). They are actually the LEDs which this driver was originally developed for, I think.

The CBT-140 and the new CFT-90 can take even higher amps, officially up to 28A, but probably even more.

Please do make a thread on your ideas!
I don’t understand how to “read” your graph yet…

My light was focused very carefully by running the LED at 30mA and shining it on a tree 30m away. The measuring was done in 12m distance (I originally thought 8m would be the minimum distance, so 12m sounded good enough).

Did you take a look at sma’s test which I linked to? He showed that 2.5m is the real minimum for the Olight SR-95 UT. What does your method tell you for that light?

I know that my conversion factor is not really based on anything, but 100m distance is something I have read in other places regarding the Maxabeam with it’s Xenon bulb.

The Miller, The plastic center is probably a plug covering the hole for the return wire in the original short arc Maxabeam

That super tight beam is sexy! I love throwers and I didn’t pick up this hobby for the sake of practicality!

This light is quite similar with the on-going BLF GT, and your beamshots can definitely satisfy our thirst of seeing the BLF GT beamshots lol.

This almost makes me want to build a big thrower light, very nice :+1:

The BLF GT has a very similar sized head, yes. But there are some differences.

  • The GT doesn’t have an electroformed precision reflector, is has a standard aluminium flashlight reflector (so it’s less precise, but has a higher reflectance)
  • The GT has 4 or 8 batteries, my light just three and also more mass at the head, so it will probably be much heavier
  • The XHP-35HI has 6-times the DIE size of the Osram Black Flat and 55 prozent of the luminance. So the spot will be much bigger, it will be much brighter overall, but it will not go quite as far
  • The GT will be factory focussed which is nice

Well known modder Vinz had a lot of difficulty getting a de-domed XP-G2 correctly focussed an an Olight SR-90 reflector (100mm diameter) a few years ago. He did manage to do it though and it held the “record” for over three years (900kcd). It originally inspired me to do this project. So putting the even smaller Black Flat into the even larger GT reflector might not work or at least be very difficult.

When you make a LED reflector light with such extreme focus, there are some unusual side effects. Many of you have probably noticed that most lights produce a slight donut hole when you hold them close to something.
Well, this light still produces a donut hole in 3m (9.8ft) distance!
You can see this on some of the beamshots, the beam looks “hollow” for the first few meters.

Here is a realistic white wall shot of the hotspot in 2m (6.6ft) distance:

Since you can’t see the corona in that shot here is another one with higher exposure (corona ist now realistic, the hotspot itself is overexposed):

The reason for this is the same as for the minimum distance where one can measure accurate candela values.

this is the most powerful light I have ever seen. congrats on the project! and thank you for sharing it.

I’ll have to repeat others in saying WOW!

Amazingly well done and very well documented. Bravo!

Truly excellent work from both of you. :+1:

A fine example of echt deutsche GrĂźndlichkeit :student: Kudos!! :beer:
Everything is thoroughly prepared and documented (before and after).

And what now. Going for the absolute record?
Or just sitting on the sofa, hoping for a rerun of Schimanski?

Thanks guys!
Schimanski sounds good…
Although I prefer Magnum. :smiley:

There are still some small annoying things to take care of:

- reduce current from 5A to 4.5A by replacing sense resistor

- solve problem of loose and cracked lens

- try to get rid of the high pitched whine by using an alternative firmware version

- change voltage set points of status LEDs to better fit the discharge curve of modern high-capacity 18650s

  • replace assymetrical springs of battery carrier with symmetrical copper springs

Also I want a nice looking beamshot which showcases the 2500m ANSI range.

What a gun :exclamation: :smiling_imp:
Congrats for building up this fantastic record breaking construction.
You really make it guys.

The only thing I would like to disagree with, is that this flashlight should be “completely useless though, the spot is way too small to find anything. laughing But then again that was never our intention. The only remaining application: cloud bounce! <img src= ” /> ”.

IMO this light is extremely sensible and very useful flashlight, as cloud bouncing and even spotting a small point of light on other far away objects are some of the really important themes in context with a lot of serious science, at least in modern physics. :student:

Not to forget the infinite eternal wisdom comments on the General Spot Size Factor Theories, that one of my grand-grandvathers used to proclaime while he had to manage a totally unexpected stormy, slippery and curvey late night sidewalk, caused by just one beer too much. But after some decades of nothing but hard work, he came up with his theoretical essence, which is a brilliant piece of mindbreaking cosmic beauty. :innocent:

The fundamentel law is genious and even simple.
As long as the spot size is big enough to enlite the key hole area of my castles front door, there is absolute no problem! :crown:

There was a thread where a BLFer spoke about using simple plexiglass
He measured better light pass through then his AR coated glass and a stock lens.
I don’t know who or where but maybe somebody else does for it was met with some disbelief so he posted his exact measurements.
In this case maybe a little less good lens without that light blocking center would be just the same but better looking and much easier to replace (make a new) and cheaper.

Impressive!!! Nice read! Drooling……
Oh, and congratulations!

unbelievable!

I believe that guy. Acrylic plastic aspherical lenses I use are far better than glass one. I proved that to myself.

Wow that guy is just barely over the lux you got with the single reflector…
With some better cooling and driving the LED harder you could pass 1.6Mcd :stuck_out_tongue:
My Black Flat LED is being driven at 6A for max output.

Do you have a link to a forum thread or something about the Scheinwerfer?
I hear a lot of talk about it but have never seen any first-hand information about it, just claims of 3M cd which seems inaccurate.

About the throw record, I guess it depends on your definition of “portable”. Large fresnel lenses make it pretty easy to get huge throw numbers, but the beam is not so nice. What did you mod today? - #1519 by EasyB

Edit: of course the design and execution make a big difference to the usability of the light. For example my light in the link above I put together in an hour or so, but it’s flimsy and not so nice to use.

True, you can always just add a bigger lens and get a bigger number…
I guess we should be sorting these lights by category, like best thrower with <=150mm head, best thrower with <=100mm head, and stuff like that.

The_Driver’s searchlight here definitely wins in the sub-150mm reflector category :slight_smile: