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

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scaru
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Any recommendations for a host?
PilotPTK
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JonnyC wrote:

I have the same question as mattthemuppet, but want to say that those prices are very reasonable!  You were right, no sticker shock for me!

Glad to hear it.  I always try to use ESD Safe stickers.

PPtk

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PilotPTK
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mattthemuppet wrote:

Pilot, could you go into the programming aspect a little more please? Do you need a PIC tool or similar doohickey to flash new settings? Would reprogramming require disassembly of the light? 

Programming the PIC will require some sort of PIC Programmer - there are very reasonable ones available directly from Microchip (PICKIT 3) that retail for about 40 bucks.  There are also some open-source serial programmers available on ebay or the like for 10ish bucks that are slow, but work fine.

A chip-clip will not be required as the programming pins are broken out to pads on the circuit board (you couldn't chip-clip the QFN anyway).  Personally, I use a 5 pin female header with pogo-pins stuck in the holes to touch the programming pins, but there are lots of ways to do it.

programming pins

 

Whether you'll have to disassemble the light depends on your enclosure/host.  The optic doesn't have to be removed if you can get to the circuit board edge with pogo pins.

Additionally, I usually write code for PICs in HITECH C, but for this product, I'm going to write the code in MikroC Pro (www.mikroe.com) because it's very simple to use and the compiler is free for code under a certain compiled size.  I own a full license of MikroC, so I can release compiled hex files commercially.  I'm going to try and keep the firmware under that limit so that anyone can use a very friendly tool to change the code.  I may also cross-write the code in MikroBASIC Pro for those who aren't comfortable with C programming.  Basic is very natural language and pretty much anyone would then be able to make changes.

PPtk

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benckie
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I like 1A tint, would these be suitable for D & C mag's with flat heat sinks to mount the unit.

rschultz101
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basic sounds good to me.  no clue on programming,...

for housing, working on it:

1x 3up
2x 3up
 going to be  DIY KIT , including, cable, remote switch, and mount.
the 1x3up going to be round, for the 2x3up, thinking square .
preferable, the housing, should only need 1 screwdriver /hex to assemble.

Sirius9
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excellent job, I especially like those "easy to access" programming pads, very convenient, this can easily be made in 5-pin connector Smile

although over my pay grade (fully assembled module is about 1/3 of average monthly salary over here) I think that the prices are very fair, I look forward to  see how will a professionally soldered module look like (clean and neat job) :d

 

JonnyC
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scaru wrote:
Any recommendations for a host?

I'm wondering the same.  Normally I try to find a driver/emitter for a specific host, but this time I will find a host just so I can run one of these Smile

PilotPTK
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scaru wrote:
Any recommendations for a host?

Not yet, I've actually ordered a number of hosts that I think might be a good fit - Most of them, unfortunately, are shipping from china and as such won't be here for a month or so..

Once I have them, I'll test fit the module into them and let everyone know the results.

PPtk

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scaru
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Anyone know would this fit in a d maglite? Maybe if the head was drilled out.
fishinfool
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Aloha and welcome to BLF rschultz101!

 

Don wrote:

"But as I said long ago, you are more likely to be killed by a dead fish dropped by a seagull in the Sahara Desert than by a lithium ion

NightCrawl
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This module: 35mm

ID of Mag: 48mm

scaru
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NightCrawl wrote:

This module: 35mm

ID of Mag: 48mm

Oh, I must have missed that. Thanks. Smile
NightCrawl
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No prob. Smile

At first I thought I should add some phrases concerning a good heatsink, maybe modding the upper part of the host and so on.. then I noticed that the posters name was scaru. Big Smile

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What is the height of the module with and without the optics?

If anyone wonders... inside diameter of the Mag D body, where the head screws on is 34mm, and outside diameter is 44mm.

Viktor

This is my flashlight collection.

scaru
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NightCrawl wrote:

No prob. Smile

At first I thought I should add some phrases concerning a good heatsink, maybe modding the upper part of the host and so on.. then I noticed that the posters name was scaru. Big Smile

Not quite sure I'm deserving of that compliment. :8)
raccoon city
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It's good to have you here, rschultz101!

benckie
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viktori wrote:

What is the height of the module with and without the optics?

If anyone wonders... inside diameter of the Mag D body, where the head screws on is 34mm, and outside diameter is 44mm.

Viktor

Maglite D flat heat sink top row second from the left

http://www.britelumens.com

Thats what i was thinking, just tap and die the center hole

PilotPTK
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viktori wrote:

What is the height of the module with and without the optics?

If anyone wonders... inside diameter of the Mag D body, where the head screws on is 34mm, and outside diameter is 44mm.

Viktor

The full mechanical specifications can be found in the original post, but the height is 15.4mm.  I always assume a little slop due to manufacturing tolerances and leave 16mm of clearance.

PPtk

Edit: Without optics, the tallest thing on the circuit board is the Inductor.  Without optic the total height is 0.4mm (circuit board) + 5mm (Inductor) = 5.4mm.  

The XM-L emitters are 3.02mm tall, so the height of the emitters is 0.4mm + 3.02mm = 3.42mm

Those numbers are a LITTLE low since there is some solder between the inductor/emitters and the circuit board, but at most the solder accounts for an additional 0.127mm (5 mil solder stencil).

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
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Almost There!

BareBoards

PPtk

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scaru
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viktori
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Oh, wow. Man, you are such a tease. Smile

This is my flashlight collection.

PilotPTK
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viktori wrote:

Oh, wow. Man, you are such a tease. Smile

That wasn't a tease..  This is a tease Smile

CloseBare

CloseBare2

 

Hehe..

 

PPtk

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NightCrawl
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PilotPTK wrote:
Hehe..

PPtk

I can actually SEE the dirty smile on your face right now!

PilotPTK
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NightCrawl wrote:

PilotPTK wrote:
Hehe..

PPtk

I can actually SEE the dirty smile on your face right now!

Haha, That's great Smile  Look really closely into the 24 karat gold pads and you're probably right, I'm sure I'm reflected in one of them Smile

PPtk

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PilotPTK
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For those who are intending on purchasing a DIY Kit, here is the assembly drawing - shows which part goes where.  All of this information is on the Silk-Screen of the board, but I find it much easier to build when I can look at a reference (and possibly even make notes on it).

Assembly Pic\

PDF Copy

PPtk

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Foy
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Pilot:

I'm in for this one: Cool white U2 Flux 1C Tint, fully assembled module. Can't wait to review this bad boy.

Just tell me where to send the Paypal and when.

 

Foy

No referral links and nothing embedded . . . ever.

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PilotPTK
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Foy wrote:

Pilot:

I'm in for this one: Cool white U2 Flux 1C Tint, fully assembled module. Can't wait to review this bad boy.

Just tell me where to send the Paypal and when.

 

Foy

I thought you were NeutraWhiteLovingFoy ? ?

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.

texaspyro
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Gold plating for solder pads can be a bad thing!  Gold tends to form intermetallic compounds with lead/tin/aluminum (google "purple plague" for a well known example).  These can be brittle and poorly conductive.   Components have been known to fall of circuit boards...

NightCrawl
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PilotPTK wrote:

Foy wrote:

Pilot:

I'm in for this one: Cool white U2 Flux 1C Tint, fully assembled module. Can't wait to review this bad boy.

Just tell me where to send the Paypal and when.

 

Foy

I thought you were NeutraWhiteLovingFoy ? ?

He'll buy both versions anyway, we know the Foy, dont we? Wink

mattthemuppet
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looking great Pilot, can't wait to see these in action.

About the programming - can the controller chips be supplied programmed off the board for self-assemblers or can they only be programmed after assembly using the pads on the board?

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