Astrolux EC01 with added display, RGB, UV, and instrumentation

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tterev3
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Astrolux EC01 with added display, RGB, UV, and instrumentation

Here’s my Astrolux EC01, which now has an OLED display, RGB, UV, MELD UI, voltage/current/temperature instrumentation, touch sensor for peek mode, and retains the charging feature.

I figured it was time to try out a 21700 light and see how many features I could add, so I got the EC01. In the past with my lights with added displays, the display has to use the space occupied by the charging port, but fortunately the head on this one is just big enough to fit the display right above the switch. This location makes for a much nicer user interface, and let me retain the stock charging hardware.

I started by milling out the space for the display:

And painstakingly squared up the corners with a small chisel shape ground into a hobby knife blade:

Once convinced the display could fit I knew what the electronics would look like, so I started on the driver. With a small amount of reverse engineering I knew what parts could be removed and identified the connections I would need:

From there it was a lot of wiring under the microscope. I had to cut a trace to insert my 10 milliohm current sense resistor in series with the battery, and then added the INA219 power monitor as well as one of the new 7135 regulators in the space left by the original microcontroller:

Then my new microcontroller board went on top, mounted to the surfaces of the two 7135 parts. This board is a small custom breakout board for the PIC18F26K40:

The three other 7135 regulators were added and wired in, as well as a TTP223 capacitive touch sensor for the touch panel above the display:

To allow firmware changes after assembly, I drilled a small hole through the board and broke out the programming connections to a small board also cut from flex PCB stock (photo taken later in the process):

For the R, G, B, and UV LEDs I hand-cut a board from blank flex PCB stock material which fits around the stock XHP50 emitter:

This board is very thin because it’s flex material, so after gluing it down to the stock copper star the overall height is change negligibly:

Time to move on to the display. This is a cheap 64×32 pixel white OLED display with an I2C interface. It requires a few support components which I wired directly to the flex connector:

A strip of copper tape for the touch sensor is added to it, and then I slid that assembly into the pocket and covered it with a window cut from 0.5mm polycarbonate:

The connections get insulated with Kapton and they fold down to fit beside the reflector:

After adding a thermistor to the color LED board and cutting a plastic insulator/spacer to hold up the reflector, here are all the parts ready to be joined up. At this point I also had replaced the wires from the switch board with the same 34AWG wire to save space:

And after lots of wiring here it is, ready for testing and firmware debugging:

For working on the firmware I set it up like this in a stick vise:

The firmware went relatively smoothly since this was so similar to the SDmini. I just needed to add support to indicate charging and to adapt to the different hardware (7135 + FET). Now for the scariest part of any of these builds (which I call THE SQUEEZE):

There wasn’t really any issue fitting it in though, there was a lot of space in the driver cavity. It just required a lot of care to avoid pinching wires. Here’s the view from the top with the LED board installed:

And optics reinstalled:

The color beam patterns are typical of this arrangement, but not too bad:

On-board charging is a new feature for my lights of this type:

And here’s a quick demo video of how the display looks in use:

Thanks for reading!

Edited by: tterev3 on 03/04/2020 - 17:09
M4D M4X
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i am WOWed!   

PLEASE NOTE
i do not work in "reviews, deals and codes" for the time being
maybe M4D M4X will return one day, but until then:

THANK YOU FOR YEARS OF YOUR SUPPORT AND FRIENDLY CONTACTS!

andrx
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wtf cool

Nicolicous
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Shocked

WOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOW

Nico -.-

AguassissiM
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@tterev3

O wow, Cool just an awesome build, Thumbs Up thank you for sharing. Beer
Have a couple of questions: is it for sale and how much is it? Big Smile
I needed a moment to lift my jaw off the floor…

***Rofis MR70*TurnRaise*Catapult V6*BLF Q8*BLF Mini*BLF Micro*Haikelite MT09R* Convoy C8*BLF D80v2 SST40*MatemincoX6S*AstroluxFT03-xhp50.2*AstroluxFT03-sst40*BLF-LT1*AstroluxFT03S-SBT90.2***

phouton
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Incredible. What a mod!

junkiexl
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awesome

Thanks for sharing!

CNCman
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That is Super Human Crown
.
“ tterev3 “ , this is unbelievable, Wow, you should have put this in the “ Old Lumens contest “ , it would have won first place easily. Big Smile
.

flightless22
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Incredible build. Thanks for posting the details.

Spaghetti code personified…

rizky_p
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WOW!!

my mind is blown.

toddcshoe
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Excellent job sir.

I better never hear anyone complaining about not being able to replace a driver or emitter on here again. EVER!!!!!!………………..sarcasm mode on. Big Smile

"Everywhere I go, there I am"

G0OSE
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Excellent, you should have entered the OL Compo!

Skylight
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Wow, excellent work. Shocked Cool

I’ve never seen a display on other flashlights than Imalent. This is like a preview of the future of flashlights in ten years. Someone please forward this to Sofirn, we want to have this produced until next year. Wink Big Smile

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This is out of my mind, can’t even imagine to modify like that.. Awesome work! Beer

Xandre
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Super !

I really like it -

Regards Xandre

Discharger
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Unbelievable! Certainly the best mod I have ever seen while lurking here, and imho quite likely the best flashlight mod ever.

The concept is also great. Basically every feature one could think of, all in the one flashlight.

I would love to have such a light and I suspect so would many many others on this forum and elsewhere. Seriously, it would be brilliant if you could design a BLF light in conjunction with Sofirn. I know I would buy one!

vinte77
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leftdisconnected
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Thanks to this thread, the site is now over-budget for superlatives for the month, so I can’t use any of those, but this is [superlative] good and thanks for sharing it. [superlative]!

RobAllen

Relampago
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But can it run Crysis?

“Electricity is really just organized lightning”
― George Carlin

skinny_tie
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Absolutely incredible work as usual. I don’t think there’s anything else like the MELD UI.

forsh
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id buy that

thats super cool!

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Th558
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Wow! this is amazing. Would love to see more manufacturers doing this especially on bigger lights like the MF01S.

gchart
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Wow. Just wow…

I’ve been contemplating adding one of those small OLEDs to a flashlight a while, just received some in a week ago. But I see you’ve beaten me to the punch… by 3+ years Facepalm

I also just received some of those TTP223’s in two days ago and have been playing with them. Incredible little chips, I’m surprised that I just now found out about them. Amazingly low quiescent current, very responsive, and flexible (momentary/latching, high/low option, etc). These will certainly be making their way into some of my flashlights. Had I known about them earlier, one would be in this year’s OL competition.

I also continue to be impressed by your ability with the enameled/magnet wire. Might impressive using that teensy-tiny stuff and keeping it all straight.

LumenMax
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Well done! Well done!!!!!

patmurris
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Spectacular! Shocked

forsh
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anychance youcould do a break down on how much this would cost

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tterev3
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forsh wrote:
anychance youcould do a break down on how much this would cost

Not much. Off the top of my head:
Display $3
Microcontroller $1
Power monitor $1
Touch sensor $0.1
7135s $1
Various passives, wire, materials $4
RGB emitters $6
UV emitter $10
Breakout board $0.3

So in total the added components probably cost less than the host light

Tom E
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Stunning Work! We do need to get there - features many lights could/should have.

Didn't even realize you did a similar to mod to a SD Mini 3 1/2 years ago! The SD Mini is still one of my favorite lights all time.

ChibiM
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Very impressive!

forsh
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i have to bump this again to ask ,how much would one of these cost to make

and how much wont one cost to buy retail

thanks man, im super impressed

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tterev3
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forsh wrote:
i have to bump this again to ask ,how much would one of these cost to make

and how much wont one cost to buy retail

thanks man, im super impressed

I answered above. Total added parts about doubled matched the cost of the original EC01 ($30)

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