Custom 17mm 5Amp PWM-less linear driver-preliminary

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led4power
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Custom 17mm 5Amp PWM-less linear driver-preliminary

Problem:serious lack of high quality high current user friendly drivers,especially in 17mm size,1xLi-ion

Solution:only possible-design it

From blank piece of paper few months ago to this:

Features:

-input voltage 2.8-4.35V

-5 Amperes(default) current

-off-time mode memory

-no components on spring PCB side!

-place for decent size (up to 8mm bottom diameter) spring on spring side pcb

-PWM-less TRUE CONSTANT CURRENT on all modes-no acustical or EMI  noise

-significantly longer run-times on lower modes compared to PWM-based(FET or AMCs) drivers-even >2x possible

-stays in regulation on lower modes for longer periods of time compared to PWM-based(FET or AMCs) drivers

-6mohm power mosfet

-pmos reverse polarity protection

-calibrated voltage reference

-less than 100uA parasitic current in sleep mode (40uA typ.)

-enough space for easy led wires soldering(up to 20AWG,22AWG recommended)

-2.6mm total thickness(including 1.6mm PCB),16.9mm diameter

 

-simple,intuitive UI,no disco modes

-modes: 0.3%-1.5%-20%-100%,standard half press to increase mode

-0.3% disable via solder "moon" 1 (no solder mess on gnd ring anymore)

-"turbo" mode option (140%@4.2V,drops linearly to 110%@2.8V),turbo enable via solder moon 2

-tailcap switch and electronic side switch capable,independently or both at the same time with single firmware!

-three  separated e-switch user interface types(rather than one complicated)

-2-step low voltage protection(3V-restricted power; 2.8V-sleep)

-over-temperature protection (threshold change possible by user)-disabled by default

 

Over-temp. protection set:

A.)Tailcap switch

Turn on the flashlight and wait until temperature rises.10-15 fast half presses sets current flashlight tempererature(driver temp to be more precise) as temp. threshold(some blinks).If flashlight becomes hotter than temp. threshold,driver adjust current to maintain temperature at threshold level.

To disable overtemp. protection:>15 fast half presses(some blinks)

B.)E-switch

Turn on the flashlight and wait until temperature rises.Holding button switch pressed for 12-15 sec sets current flashlight tempererature(driver temp to be more precise) as temp. threshold(some blinks).If flashlight becomes hotter than temp. threshold,driver adjust current to maintain temperature at threshold level.

To disable overtemp. protection:Holding button switch pressed for 15-20 sec (some blinks)

Note:do not run this driver "in air" because even with activated overtemp. protection,temp. rise may be faster than driver could decrease current fast enough to protect itself.

 

E-switch user interfaces:

1.)UI_1-"standard" UI

-normal button switch press increases mode: sleep->(mode0)->mode1->mode2->mode3->sleep

-double press decreases mode

-long press from sleep->max mode

2.UI_2- Smooth Ramping UI

-when switch is pressed(flashlight is turned off) driver starts to ramp current up or down from current that was stored as last one(this means driver remembers last current before shut down),release switch to stop ramping

-pressing switch again- driver ramps current in opposite direction

-if switch isn't pressed for more than 1.5sec,driver goes into sleep on switch press

-it takes about 4.5sec from min to max or from max to min

-one blink at 50% current,2x blink when current=max.

-10 bits resolution on lower currents,8-9 bits on higher currents

3.UI_3 "Simple UI"

- double press increases mode

-single press->driver shuts down

-single press from sleep->last used mode

 

How to set UI:

-turn the flashlight on and hold button switch pressed for 7-12sec(some blinks).UI is changed to next one.Repeat to get UI you want.

 

Other:

 E-switch protection:

-if e-switch is pressed for more than 20sec(accidentally in pocket,bag etc.),driver shuts down

Connection diagram:

 

This driver(older version) Vs 105C:

                           

                            

Approx. estimated price: 12-14$/piece (min. 4pcs order,but with free worldwide shipping)

More additional info later.

Edited by: led4power on 06/29/2014 - 07:23
Old-Lumens
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Sounds fantastic.

Will you send one to HJK for testing and review?

Will you be offering these for members in full ready to go form or in kit form?

What kind of price if you do?

Thank you

 

Edit: Can changes be made for it to do 9 amps or more?

Are you looking at a driver specifically for the MT-G2 any time soon?

 

Edit II: lol

Can these run master slave?

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

WarHawk-AVG
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WOW…nice!

Interested for sure

Can’t be cheap…and sure isn’t gonna be DIY

pinkpanda3310
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Very nice. I am interested if you do offer these for sale.

  

Rufusbduck
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Don’t tease me bro.

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

Scott

djozz
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Very interesting driver, both very high current capable and current controlled low modes, that is fantastic. Looking forward to the final driver Smile !

DARCANGEL
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Very cool idea and quite a low profile compared to the105c.It's an impressive concept and +2 on sending one to HKJ for testing.I would assume mode programming is done through the side switch?I like the 140% for turbo and I'm wondering if the turbo steps down at all or can it go till voltage is too low.Sorry for the questions,not really familiar with a fet driver.

borstar_micke
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Great work!

Will def be interested in a couple of these babies! Smile

Firelight2
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Wow!!!! Looks awesome!!!!

Gj
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Would sound great even @ 20mm.

DayLighter
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definitely interested in owning several of these if it ever goes on sale Big Smile

The only way to do a great work is to love what you do.

rollinstone157
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I sure hope these will be available for purchase some day, this is amazing. Great job.

FlashPilot
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Here’s my money… please take it from me for several drivers! :bigsmile:

Sirius9
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OK, I am interested Smile but, it would really be nice to have -8.4V input

 

TexasToasted
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Sirius9 wrote:
OK, I am interested Smile but, it would really be nice to have -8.4V input

I would be really happy to have a 2-cell version of this driver.

ImA4Wheelr
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Sounds great.  Hoping you branch out to a 2S version. 

RMM
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Very nice! I am looking forward to this driver.

Mountain Electronics : batteries, Noctigon, and much more! What's new? 

Firelight2
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You should sell this driver through Mountain Electronics. I’ll buy several.

AlexGT
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I want one! How much? PayPal ready! Love

scottyhazzard
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Very cool.

"Those who hammer their guns into plows will plow for those who do not."

freeme
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Subscribed.

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bibihang
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It’s a near perfect driver but since I’m not from USA and wonder how much does it cost to get one if you are willing to send it to my country.

musicmagic
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…and the BLF custom driver parade marches on.

If you can’t blind them with your brilliance, baffle them with your bullcrap.

The real currency in the world is not money, it’s trust.

Rufusbduck
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comfychair wrote:

How does, say, 2.5 amps give a longer run time than 5 amps 50% on/50% off PWM’ed output? Does that only work with cells that have a big difference between capacity at high currents vs. capacity at low currents?

What happens to that wonderful 5 amp output with a single XML2 when input voltage falls below 3.8v?


Pilotptk explained it and I’ll take his word for it. LEDs are also more efficient at lower currents and pwm is high current, high frequency. Low modes are simulations of low current output but with high Vf issues. 100 % of 1.5A is more efficient than 50% of 3A.

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

Scott

DBSAR
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Definitely interested in a couple of these if you offer them for sale here. Smile

That Canadian flashlight guy & Lantern Guru -Den / DBSARlight

WarHawk-AVG
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Rufusbduck wrote:
comfychair wrote:

How does, say, 2.5 amps give a longer run time than 5 amps 50% on/50% off PWM’ed output? Does that only work with cells that have a big difference between capacity at high currents vs. capacity at low currents?

What happens to that wonderful 5 amp output with a single XML2 when input voltage falls below 3.8v?


Pilotptk explained it and I’ll take his word for it. LEDs are also more efficient at lower currents and pwm is high current, high frequency. Low modes are simulations of low current output but with high Vf issues. 100 % of 1.5A is more efficient than 50% of 3A.

Plus it’s less stressful on the LED
nofearek9
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interesting.

comfychair
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Everything is the most awesome thing ever, sorry to have rained on anyone's parade.

pinkpanda3310
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Low modes are simulations of low current output but with high Vf issues.

I don’t want to fan any flames here but I don’t understand this statement. Can someone put it in layman’s terms for me?

  

comfychair
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20% with a 5A output driver using PWM will do 5 amps for 20% of the time, and 0 amps for 80% of the time. The Vf required to get 5 amps through a XML2 is 3.75-3.80A. Tailcap amps will be a measure the average current, around 1A.

But, a non-PWM constant 1 amp into the same LED only needs an output voltage of 3.05-3.10 volts.

Ledsmoke
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How preliminary is this preliminary? 2 weeks off or 2 months?

Do you have an approximate price range?

Can you expand on how the user can change the modes? IE programmed through the switches or through hardware programmer like the Atmel chips?

 

BTW: SOOO COOOL! Big Smile Looking forward to seeing more of these. A lot more!

~ Ledsmoke ~

Dutch humor:

[quote=djozz]

 I do not think that the BLF-community ben

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