My entry to the scratch built contest.

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firehopper
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My entry to the scratch built contest.

I have most of the parts I think.

2 – 10 watt leds.
2 – heatsinks
2 – reflectors and lenses for the leds
2 – 10 watt drivers than can be hacked to accept pwm
1 – psoc 4 dev board
1 – 12 volt 4.5 ah gel cell.
1 – 12 volt > 5volt switching regulator
1 – 10K -100K POT for dimming controll
1 – switch of some type. not sure what kind of switch I want. possibly another switch for modes as well.
some pvc pipe to fit the led heatsinks along with pvc pipe caps x2,
some screws and metal strapping. and possibly paint.

have switch, pvc pipe and endcaps.. one led installed into endcap.. working on second one.. pictures were taken, will upload them and post them soon.

images

Psoc4 devboard.
the psoc4 devboard

12volt to 5volt adjustable voltage regulator
12volt to adjustable voltage switching regulator

the two drivers, one modified for pwm input
the 2 10 watt drivers, one hacked for pwm

front of driver board it uses a pt4115 driver chip, pin 8 is the pwm input, pin 4-7 is ground of the pwm input. so connect a wire from anyone of those to the ground of your pwm signal Smile
IMG_1025

schematic of the driver board some values are guesses.
led driver circut

rear of driver board
IMG_1026

the 2 10 watt leds, one cool white, one warm white. yes. I’m mixing tints.. we shall see what happens Smile
2 10 watt leds,

the cool white led with reflector, lens and heatsink
cool white led with reflector + lens

the warm white led with reflector, lens and heatsink
warm white led with reflector and lens

Edited by: firehopper on 06/14/2014 - 10:54
firehopper
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this is the current version of the main.c firmware file..
short and sweet.. cant test it till I get a few small parts Smile

Pot is a 50K ohm pot, got that attached to the psoc 4 board, it has a led on pin 1.6 so I’m going to use that pin to send pwm to the drivers that way I have a small indicator led that shows when the big leds should be glowing..

some tweaking of the code. and it does work now Smile so now I could work on modes and stuff.. but first I’ll attach all the parts together and give it a smoketest Smile

I’ll do that tomorrow, and take photo, and maybe a short movie of the test Smile

———————————————-
okay cant post the code directly. forum software collapses spaces for some reason.. dont know how to turn it off..
flashlight code

screenshot of the code in psoc creator
by Keith Miller, on Flickr">the code for my flashlight :)

internal schematic of the psoc4 just 3 parts, a bootloader block, a pwm block, and a adc block. Smile thats it.
circut thats inside the psoc4

firehopper
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videos!

test in the dark

close up of my bodgy wiring job to get it to work without a case Smile

firehopper
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this is work in progress.

parts for the case
case parts for my flashlight

endcap with hole cut in it for lens
hole cut in end cap for lens

led installed
another shot of led mounted

underside of the led
this heatsink/led is just push fit.. its actually tight enough to not need any screws to hold it in place.

test assembly to see how it looks.. handle and power switch installed also.
another shot, this time handle and switch are also installed

switch and handle close up
showing off handle and switch

a bit more work done on it today before work Smile

ventilation holes cut in front endcap
ventilaton holes cut in tops

rear endcap with hole cut for fan
endcap with hole for fan

rear endcap with fan mounted
fan mounted on end cap

side shot showing dimmer controll mounted as well..
dimmer pot mounted, nearly finished side shot.

its finished, not perfect, but its as finished as I can make it at the moment. had a car crash a week ago. and have run out of free time.

shots of finished flashlight

IMG_1523

IMG_1524

firehopper
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here find the beamshots and videos Smile

its not really a good thrower, its more of a flooder or for close up use..
it would be good for emergency use.

but hey I had most of the parts just lying around Smile so free light Smile

MRsDNF
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Cool . I'm here with popcorn.

 

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.

 

Ledsmoke
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Interesting build. Looking forward to see what you come up with for a body for the parts you allready have.

~ Ledsmoke ~

Dutch humor:

[quote=djozz]

 I do not think that the BLF-community ben

firehopper
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I plan on uploading more pictures to the first post of parts as I get them Smile

bushwhacked
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Way too complicated for me. Looks interesting.

P60dropins.com (just a redirect for now)

firehopper
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bushwhacked wrote:
Way too complicated for me. Looks interesting.

thanks sir Smile

firehopper
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Ledsmoke wrote:

Interesting build. Looking forward to see what you come up with for a body for the parts you allready have.

well its prolly gonna be ugly white or gray or black pvc for now.. maybe I’ll come up with a way to make a wood body for it.. Infact its given me ideas, but shhh Smile

but for now, prolly ugly pvc

firehopper
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yup posted a bunch of pictures Smile
a bit more progress!

firehopper
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code is ready for testing. it does work with a small testing led.. so onward!

Ledsmoke
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That is awesome. I wish more big ass lights came with this. No BS light bars or color changing leds. Just a display. Simple. Good job Smile

~ Ledsmoke ~

Dutch humor:

[quote=djozz]

 I do not think that the BLF-community ben

firehopper
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Ledsmoke wrote:

That is awesome. I wish more big ass lights came with this. No BS light bars or color changing leds. Just a display. Simple. Good job Smile


I’m confused, I dont have a display in this build, not yet anyway.. just a simple regular led that glows at the same time as the main led.

was pondering putting a small lcd or oled or 7-14 segment led display.

ImA4Wheelr
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Ain’t nothing wrong with a PVC build. I know there are a few fans of it here. Me being one. Check out my holy hot spot Batman thread for proof.

Looks like this will be the most advance build FW wise, which is where the real future of lighting resides. Keep up the good work. Smile

firehopper
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ImA4Wheelr wrote:
Ain’t nothing wrong with a PVC build. I know there are a few fans of it here. Me being one. Check out my holy hot spot Batman thread for proof.

Looks like this will be the most advance build FW wise, which is where the real future of lighting resides. Keep up the good work. Smile

thanks, just checked my pwm freq with a ‘scope. and its around 4khz.. is that good? I can prolly go up to maybe 10khz, possilbly Smile

JohnnyMac
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MRsDNF wrote:

Cool . I'm here with popcorn.

Me too!  Looking like this will be interesting. Big Smile
firehopper
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JohnnyMac wrote:

MRsDNF wrote:

Cool . I’m here with popcorn.

Me too!  Looking like this will be interesting. Big Smile

thanks for watching Smile

ImA4Wheelr
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Sorry, I’m not a good judge of PWM. Traditional SRK’s don’t even bother me. I only avoid it when working under the hood or with other dangerous moving machinery. 4K sounds good to me though.

firehopper
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ImA4Wheelr wrote:
Sorry, I’m not a good judge of PWM. Traditional SRK’s don’t even bother me. I only avoid it when working under the hood or with other dangerous moving machinery. 4K sounds good to me though.

well I don tthink someone (me) will use this under the hood or under a car Smile well I could but its kinda overkill for that use Smile
anyway. maybe tonight or tomorrow I’ll get everything wired together and post some short videos of it actually doing something before I get some pvc parts to try and package it up Smile
firehopper
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two videos of the guts working.. now to build a case Smile

MRsDNF
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SmileI'm up to wiring as well. When do you think you can come around?

 

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.

 

firehopper
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MRsDNF wrote:

SmileI’m up to wiring as well. When do you think you can come around?

what help you wire yours up? naw.. Smile I gotta build my case yet..

Rufusbduck
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I spend most of my time on the host and as little as possible on the driver which is silly given the driver is the heart. Nice to see it being done the other way around.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

firehopper
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Rufusbduck wrote:
I spend most of my time on the host and as little as possible on the driver which is silly given the driver is the heart. Nice to see it being done the other way around.

I think I spent maybe 10 mins total on the code. more time was spent attaching wires to things and connecting the wires together Smile my code is simple.. about 10 lines long..
unless I decide to put modes and or a indicator/display of some sort on it.
Rufusbduck
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A lot more in there than just code but even your minutes spent are more than I do.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

firehopper
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Rufusbduck wrote:
A lot more in there than just code but even your minutes spent are more than I do.

thanks I think :>

anyway.. tomorrow I hope to get some of the parts to start making the case.. and a power switch Smile

firehopper
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Bump for update in first post, new photos will be posted shortly

MRsDNF
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Those couple of leds are really pumping out the light. Have you had extended runs yet? I was just wondering how well the heat sinks work.

 

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.

 

firehopper
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MRsDNF wrote:

Those couple of leds are really pumping out the light. Have you had extended runs yet? I was just wondering how well the heat sinks work.


not together no.. but the cool white heatsink does get warm.. not hot but warm, the driver.. very warm almost hot.. so there will be ventilation, will mount a fan to each “cannon” I’m pondering calling it a light faucet.. and maybe getting a waterfaucet handle for the pot Smile

when pwm’d the drivers and heatsinks dont get warm really.. under say 80% full..

I’ve got a handle mounted, mounting main power switch shortly.. then I have to drill vent holes for the led heatsinks.. then figure out how I’m gonna mount the fans and cut vents for those Smile
then I can cut holes for the wires that have to go between each pod.. then attach the pods together and start wiring things together, taking lots of photos as I go.. Smile

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