YuvalS's Hand Made Class, 10th Annual BLF/OL contest entry topic

YuvalS · 2022-10-27T13:20:45.000Z

Hoop:

Nice work YuvalS.

MtnDon:

Looking good.

Thanks guys.

Since I have already had the drill in reach, I also started drilling the housing.
first is the hole for the momentary switch.
Because of the partition exactly in the center I was not able to drill it in the center.
I have drilled it on the left side but wanted to keep it as close as possible to the middle, so I had to sketch on the housing.

It will fit perfectly behind the PCBs

I also drilled a hole for the cable gland, also trying to keep it close t the plates to leave enough room for the electrnics.
The cable will be coming from the rear battery box.

Before I can add the emitters, optics and electronics have to connect the GoPro mount and think of a way to attach the microphone

MtnDon · 2022-10-27T14:07:10.000Z

YuvalS:

Because of the partition exactly in the center I was not able to drill it in the center.

I like asymmetrical designs

YuvalS · 2022-10-28T12:57:45.000Z

Today Is the last weekend before the deadline so I am planing to work non-stop until I complete the light.
Be prepared for an new update post every few hours :)

I want to have an external microUSB port for FW updates and for adding/changing the voice commands easily.
I had to de-solder the USB port from the Arduino and re-solder it using an extension wires.

After soldering, I have reinforced the solders with hot glue.

In order to save some space inside the housing, i have removed all the pin headers from the Arduino board.

YuvalS · 2022-10-28T16:40:03.000Z

While it is still reasonable to make sawing noise, I cut the plastic for the battery box.
I saw the box out of 2cm thick plate.

Covered it from both sides to create a box, using thin Perspx sheet.
I glued everything together to make it waterproof and reinforced with screws.
The cover will held close using latches to make it easy to change batteries while caving.

I connected the other side of the latches (have no idea how it is called) to the cover using screws and glued rubber to to seal the opening.
Also Added a cable gland for the power cable.

MtnDon · 2022-10-28T19:09:01.000Z

(have no idea how it is called)

“Catch plate”, orsometimes “hook”

YuvalS · 2022-10-28T20:12:20.000Z

MtnDon:

“Catch plate”, or sometimes “hook”

Thanks, everyday you learn something :)

I want to use screws for connecting the GoPro mount to the housing since a lot of force is applied on this point while tilting the lamp (and when banging the helmet in the cave ceiling).
Because the housing is mad of thin Aluminium, I decided to tap the mount.

In order to add strength and also improve the heat dissipation by conduction some of the heat to the mount, I have also glued tho mount using a heatsink plaster.

Screwed everything together and have to wait for it to cure.

Hoop · 2022-10-29T04:21:18.000Z

MtnDon:

(have no idea how it is called)

“Catch plate”, or sometimes “hook”

Those are called “draw latches.” Also known as tension latches, according to Mcmaster-carr.

YuvalS · 2022-10-29T11:46:22.000Z

Hoop:

Those are called “draw latches.”

So today I also learned something new :)

this is actually the last day for the build because i don't have any more time and I have to complete the light today.

Did some more drillings.
For the microphone I had to drill trough the GoPro mount and it was hard to measure and place the drill bit.
Luckily I was able to drill from the inside, via the switch hole.

And it went almost as planned (this screw was already filled to correct length)

Also drilled a hole for the USB port.

MtnDon · 2022-10-29T12:44:50.000Z

Re: the latches… Yours are also “over-center toggle latches

Link.

YuvalS · 2022-10-29T17:54:28.000Z

Time to work on the electronics.
soldered the Microphone and added a SMD capacitor to cancel some noises.

Check everything is working before final assembly.

Isolating the microphone body (connected to GND) using a shrink tube.

YuvalS · 2022-10-30T03:07:42.000Z

Although trying relay hard I did not manage to finish the light today and I have to go to sleep (almost 5 AM) I did complete most of the work but still have some assembly left, mostly soldering.
I do have some hope to finish tomorrow before the deadline.

I glued the MPCBs and lens using heatsink plaster so it now looks like a caving light.

Also glued the microphone and button.

And added Fet transistor for the spot channel and 105c with 7*AMCs for the flood channel. protected everything with shrink tubes and soldered all wires.

Tomorrow I have to add the voice recognition module and the Arduino, solder the battery box and add the rear and front covers....

umop_3pisdn · 2022-10-30T07:28:54.000Z

Love how it all started to come together and take shape so quickly. Well, the pictures make it look quick but I know that’s some serious application of elbow grease. Good job and keep it up, almost there!

everydaysurvivalgear · 2022-10-30T09:04:57.000Z

Looking good, you are on the home stretch.

MtnDon · 2022-10-30T13:06:37.000Z

Looking great Yuval.

MascaratumB · 2022-10-30T22:42:16.000Z

Can’t wait to see this one finished and with demonstration
I guess I’d like to have something like this, voice activated !
Good work YuvalS

NeutralFan · 2022-10-30T23:22:51.000Z

A voice activated headlamp! YuvalS taking it to the next level.

YuvalS · 2022-10-30T23:29:10.000Z

Thank you guys for all the support,

umop 3pisdn:

Well, the pictures make it look quick but I know that’s some serious application of elbow grease.

Indeed everything take a lot longer than it seems in pictures (I don't post pictures of all the failures :) )

MascaratumB:

I guess I’d like to have something like this, voice activated !

Hope my thread was informative enough, I did skip some stages yesterday since I worked fast.
The code will be available in my Git repository.

YuvalS · 2022-10-30T23:35:06.000Z

Today I also hat to work into the night and completed almost everything.
I have soldered all the PCBs and other components. this build reacquired a lot more soldering than a standard light.

Also placed the front Perspex window.

And glued the micro USB port.c (probably was a lot easier to buy it from AE instead of making it by myself)

YuvalS · 2022-10-31T03:26:50.000Z

Just completed the final tasks and completed the light. Tomorrow I will update a video

Add another Perspex for the back side. Since I have enough cooling from the aluminum plates I think it will look better with a transparent back reviling the circuitry. Also the LEDs provide some info on the recognized words.

Soldered the wires for the battery box.

Colored it with some nail polish to indicate correct polarity.

lumenzilla · 2022-10-31T03:43:29.000Z

It looks promising. Can’t wait to see the final result