As requested, 3 XM-L Driver/Emitter module DIY

469 posts / 0 new
Last post

Pages

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA
As requested, 3 XM-L Driver/Emitter module DIY

At the request of more than a few forum members, I've finished up a 3-XML Module that includes the emitters, a constant current driver, and a micro-controller and is designed to mate with the LEDIL CUTE-3 Optics.

I built one up, and it works perfectly - quite awesome, in fact.  I've got the production circuit boards on order, and I'll be offering it as a kit for modders and DIYers.

Specs as follows:
35mm Diameter (Same as the CUTE-3 Optics)
Max output: 3.2Amps (up to 5Amps with one resistor change)
Input Voltage: 9-25 Volts
High-Frequency PWM Dimming (NO flicker/beat)
Microcontroller for completely customizable modes (Mode memory available)
     - Source code will be freely available once I finish it up
Driver efficiency measured at 96% (at full output) using Calibrated Benchtop Multimeter
All parts rated at minimum 125C Operation,  Many rated at 150C
All ceramic X7R Capacitors - No Electrolytic and No Tantalum to fail
0.4MM Thick FR-4 Circuit board with hundreds of thermal via's - Better performance than even the best MCPCBs
Center clearance hole for 6-32 Mounting screw
     - Screw this down to your pill and get much better thermal performance than any type of thermal epoxy or tape
3 pass-through holes for wiring
Modes can be changed by removing and then re-applying power (standard tail switch operation) (with or without mode-memory) OR
     - Modes can also be changed by a secondary momentary contact input (Power switch and Mode switch combo) OR
     - Modes can also be changed by a variable resistance - slider switch, potentiometer, etc OR
     - A variable resistance can control the brightness directly in 1024 increments - Essentially infinite adjustment
Extremely Low settings are possible - 3mA (.003A) is the lowest possible drive
Mounting holes for the CUTE-3 Series of TIR Optics
Thermal protection on board - the micro-controller monitors the temperature and can be programmed to shut-down or back-off current
Reverse Voltage Protection.
2D Print and 3D Model of the entire assembly available to help with custom enclosures or torch tubes
     - http://www.brightlightmodules.com/3XML_Module_Mechanical.ZIP 

At first, I'll be offering these strictly as a kit - you do the soldering yourself.  If there's a demand, I will consider selling completed modules built on a production machine line ( FAR better quality than hand soldering ).

** Due to obvious demand for fully assembled modules, and a obvious lack of demand for DIY kits, These will now be available professionally assembled.  DIY kits will be available upon request. **

Youtube video of the module in action

LEDSingle

LEDSingleOptics

 

Back side of circuit board - Bare Copper/Gold for Excellent thermal conduction to pill:
Thermal Conduction 

If you know you're going to want one (or more) of these, PM me and I'll make sure that you get one from the first batch.

Assembly Doc

PPtk

 

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

Edited by: mattthemuppet on 08/18/2012 - 22:54
BIGWOOD
BIGWOOD's picture
Offline
Last seen: 1 year 1 week ago
Joined: 11/17/2011 - 16:16
Posts: 702
Location: Vancouver, BC

That's awesome.  Love to hear more.

mattthemuppet
Offline
Last seen: 6 months 1 week ago
Joined: 01/04/2012 - 16:20
Posts: 1273
Location: WA

wow, that looks great!

any low voltage and overtemp protection? Rough ball park on price?

This would be well worth posting on the mtbr DIY lights forum as triple XM-L lights are becoming quite popular there. Plus, there's a guy prototyping a housing that would suit this down to the ground - I'd expect demand to take off a fair bit once that's ready as it'll be the simplest and brightest build around.

JohnnyMac
JohnnyMac's picture
Offline
Last seen: 2 weeks 4 hours ago
Joined: 04/12/2011 - 16:03
Posts: 8864
Location: Eastern PA

Looks and sounds incredible, Pilot!  Any idea on expected price?

Ledsmoke
Ledsmoke's picture
Offline
Last seen: 1 year 5 months ago
Joined: 08/08/2011 - 16:05
Posts: 1995
Location: Denmark

NICE!

I've never seen such a nice combo for sale before - what an excellent job with that high efficiency! I love it.

Same as the others  - price estimate on 1 kit?

~ Ledsmoke ~

Dutch humor:

[quote=djozz]

 I do not think that the BLF-community ben

mattthemuppet
Offline
Last seen: 6 months 1 week ago
Joined: 01/04/2012 - 16:20
Posts: 1273
Location: WA

doh! you know, I completely didn't make the connection between this and that mahoosive 4x4 light some crazy guy was building from scratch Smile That makes it even more interesting..

Hill
Hill's picture
Offline
Last seen: 9 months 1 week ago
Joined: 07/07/2011 - 07:42
Posts: 684
Location: Northeast USA

Awesome board!  Looks like you've incorporated many key features that are highly desirable.

What tint are the XML's?

Will watch this closely....

My lights here and here

 

dorpmuller
dorpmuller's picture
Offline
Last seen: 4 months 1 week ago
Joined: 10/20/2010 - 18:29
Posts: 1054
Location: Central Pa., U.S.A.

Price? Tint?

"I am the flashlight king! I can light anything!"

Chicago X
Chicago X's picture
Offline
Last seen: 8 years 5 months ago
Joined: 07/22/2011 - 16:13
Posts: 4013
Location: See Name

I'll take 5 of whatever you come up with.

Very nicely done !!!

http://wardogsmakingithome.org/index.html

War Dogs, Making it Home - Rescue Dogs for Returning Vets

JonnyC
JonnyC's picture
Offline
Last seen: 7 months 1 week ago
Joined: 01/14/2011 - 19:12
Posts: 1148
Location: Green Bay, WI - USA

This is awesome news!

What MCU are you using, an AVR?

mattthemuppet
Offline
Last seen: 6 months 1 week ago
Joined: 01/04/2012 - 16:20
Posts: 1273
Location: WA

just some questions from the guy making the 35mm housings (Zemike), here's the link

http://forums.mtbr.com/lights-diy-do-yourself/35mm-triple-xm-l-engine-785971.html

"Never saw an XM-L on FR4 substrate.

Matt, can you ask several questions on that forum?
1) what is the LED/heatsink temp on full power ?
2) minimum order quantity for a machine assembled module ?"

scaru
scaru's picture
Offline
Last seen: 4 years 11 months ago
Joined: 03/22/2012 - 13:36
Posts: 6946
Location: Virginia

When you say that we have to do the soldering, exactly how much soldering is that. Also how much will it cost? Silly

JonnyC
JonnyC's picture
Offline
Last seen: 7 months 1 week ago
Joined: 01/14/2011 - 19:12
Posts: 1148
Location: Green Bay, WI - USA

I'm curious about the machine assembly as well, considering I'm better at soldering, but don't trust myself to do all of that tiny stuff (especially doing the LED).

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

mattthemuppet wrote:

wow, that looks great!

any low voltage and overtemp protection? Rough ball park on price?

This would be well worth posting on the mtbr DIY lights forum as triple XM-L lights are becoming quite popular there. Plus, there's a guy prototyping a housing that would suit this down to the ground - I'd expect demand to take off a fair bit once that's ready as it'll be the simplest and brightest build around.

Glad you like it!

Yes and Yes.  I'll have a better idea on price by tomorrow - details then.

Once I have it more finalized, I'll post over on that forum.  Thanks for the suggestion!

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

Hill wrote:

Awesome board!  Looks like you've incorporated many key features that are highly desirable.

What tint are the XML's?

Will watch this closely....

Thanks!  Yeah, that was kind of the plan.  The swiss army knife module.

That's the beauty of a "Kit" - They're whatever tint you want them to be!

If I start manufacturing them, I'll likely offer a cool U2 and a Neutral T6.

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

JonnyC wrote:

This is awesome news!

What MCU are you using, an AVR?

PIC.  Microchip offers the PIC Controllers in higher temp ratings than AVR offers the TINY Series.  For instance, the TINY13A in the DFN package is only rated to a max of 85C.  The PIC Part I've selected is rated to 150C.  Additionally, the PIC is physically smaller.  For what they have to do in this application, it's 6 of one to half a dozen of the other anyway.

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

mattthemuppet wrote:

just some questions from the guy making the 35mm housings (Zemike), here's the link

http://forums.mtbr.com/lights-diy-do-yourself/35mm-triple-xm-l-engine-785971.html

"Never saw an XM-L on FR4 substrate.

Matt, can you ask several questions on that forum?
1) what is the LED/heatsink temp on full power ?
2) minimum order quantity for a machine assembled module ?"

He'll be plesantly surprised by the performance of an XM-L on FR-4.  I promise.

1) Completely 100% dependent on the heat-sink.  MCPCB, FR-4, Platinum - doesn't matter what the emitters are mounted on - it's the heat sink that has to dissipate 30 watts..  I can't answer the question, unfortunately.

2) Unsure just yet - I haven't even got the kits shipping yet.  Details will be provided if/when I'm prepared to offer a fully assembled module.

 

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

scaru wrote:

When you say that we have to do the soldering, exactly how much soldering is that. Also how much will it cost? Silly

For the 'kit' - I mean all of it.  You'll get a bare circuit board.  Not for the faint of heart, and I don't pretend that it is.

Pricing to be announced soon.. I'm still wrapping up a few details.

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

A few people wrote to me and asked about mechanical prints and 3d models - I'm assuming to assist in fitting this into an enclosure.

Rather than send it to everyone privately, I'm just going to post a link to the files here.

http://www.brightlightmodules.com/3XML_Module_Mechanical.ZIP

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

Lothar
Lothar's picture
Offline
Last seen: 2 weeks 4 days ago
Joined: 10/26/2011 - 11:22
Posts: 546
Location: Stellenbosch, South Africa

PilotPTK wrote:

mattthemuppet wrote:

any low voltage and overtemp protection?

Yes and Yes.

How low is the low voltage protection? Would this light engine be able to run on 2 x 18650's?

 

PilotPTK wrote:

35mm Diameter (Same as the CUTE-3 Optics)

I've had a look at both your drawings and the CUTE-3 datasheet, but nowhere can I see how far the leds are from the center or the board. Will the DRY reflector fit this light engine?

 

Thnx

Current Collection:

BLF: BLF-GT90, BLF-GT70 (CW Sliced), BLF GTmini, BLF-LT1; 

BTU: Shocker (3 x SST-40 @ 8A)

Solarforce: L2P (XM-L2 U3 @ 4A), MPP-1 (XP-L HI @ 6A), MPP-3 (3 x XM-L2 U2 @ 12A), M6 (Nichia 319A @ 6A), M8 (XHP-50.2 @ 9A), 9x (9 x XM-L2 U2 @ 2A)

Coming Soon: Lumintop: BLF-GT4; 

viktori
viktori's picture
Offline
Last seen: 5 years 2 months ago
Joined: 12/25/2011 - 02:41
Posts: 713
Location: Croatia

Incredible! Flat Stare

This is my flashlight collection.

mattthemuppet
Offline
Last seen: 6 months 1 week ago
Joined: 01/04/2012 - 16:20
Posts: 1273
Location: WA

thanks, I posted your reply on the thread over there.

I've certainly learned a lot this morning about MCPCB and FR4 substrates Smile 

I think a lot of people, both here and on mtbr would be very interested in a complete assembled board. Heck, even I would start thinking seriously about it and I already have a stupidly bright set of DIY lights. The thought of soldering the bits on myself would give me the heebyjeebies though, even soldering AMC7135 chips onto a board isn't my idea of fun!

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

Lothar wrote:

PilotPTK wrote:

mattthemuppet wrote:

any low voltage and overtemp protection?

Yes and Yes.

How low is the low voltage protection? Would this light engine be able to run on 2 x 18650's?

Absolutely not.  Minimum input voltage = 9V.  The three emitters are wired in series and this module has a buck-converter, not a buck-boost.

 

Lothar wrote:
 

PilotPTK wrote:

35mm Diameter (Same as the CUTE-3 Optics)

I've had a look at both your drawings and the CUTE-3 datasheet, but nowhere can I see how far the leds are from the center or the board. Will the DRY reflector fit this light engine?

The LEDS are arranged at 0 degrees, 120 degrees, and 240 degrees on circle that is 17mm in diameter.  Thus, the polar coordinates are 

8.5mm, 0
8.5mm, 120 and
8.5mm, 240
with the center of the module being 0, 0.

I don't have a DRY, not do I know the measurements of it's reflector, so I have no idea whether that matches or not.

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

kbark
kbark's picture
Offline
Last seen: 8 months 1 week ago
Joined: 07/12/2011 - 13:22
Posts: 370
Location: North Carolina

Subscribed. Cool

The bike light DIYers are watching...

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

mattthemuppet wrote:

thanks, I posted your reply on the thread over there.

I've certainly learned a lot this morning about MCPCB and FR4 substrates Smile 

I think a lot of people, both here and on mtbr would be very interested in a complete assembled board. Heck, even I would start thinking seriously about it and I already have a stupidly bright set of DIY lights. The thought of soldering the bits on myself would give me the heebyjeebies though, even soldering AMC7135 chips onto a board isn't my idea of fun!

Yeah, i'm getting that vibe from a lot of people - looks like I WILL be offering this as an assembled module.  The kit will still be available (and available first) for those who want to do it themselves, but I'll go ahead and plan on having these machine assembled..

For assembled modules, I'm going to have to pick a max of two or three different XM-L Tints/Bins..  What's everyone's preference?  If you had to pick two XM-L tints/bins to be available - what would they be?

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

PilotPTK
Offline
Last seen: 7 years 10 months ago
Joined: 09/04/2011 - 21:53
Posts: 1736
Location: Michigan, USA

kbark wrote:

Subscribed. Cool

The bike light DIYers are watching...

Oh, damn... Now I have to behave Smile

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

phburns
Offline
Last seen: 4 months 5 days ago
Joined: 05/03/2012 - 10:04
Posts: 1
Location: Tennessee

I'll be looking for the machine assembled versions.

What would a dual version look like, is there a way to gang the controls together for two units?

JonnyC
JonnyC's picture
Offline
Last seen: 7 months 1 week ago
Joined: 01/14/2011 - 19:12
Posts: 1148
Location: Green Bay, WI - USA

I'm going to wait for the sticker shock before getting excited Wink

Now, this could function quite well in an automotive application, correct?

NightCrawl
Offline
Last seen: 5 years 8 months ago
Joined: 01/22/2012 - 08:20
Posts: 3071
Location: Karlsruhe, Germany

@PilotPTK: I think 1A/1B/1C or sth. like that U2 and 3C T6 would be the most requested. Can you provide a low voltage protection at 13V?

mattthemuppet
Offline
Last seen: 6 months 1 week ago
Joined: 01/04/2012 - 16:20
Posts: 1273
Location: WA

yeah, it's easy to forget when you're very proficient at something that others can be less so Smile

this is all very tempting though, I may have to unsubscribe from this thread before my will completely fails!

raccoon city
raccoon city's picture
Offline
Last seen: 12 hours 14 min ago
Joined: 10/06/2010 - 02:35
Posts: 17281
Location: रॅकून सिटी Palm Desert CA USA

Welcome to the monkey house, phburns!

Pages