Powerful over bright LED light sources have now become popular and available. The advantages of LEDs are that their service life is much longer - up to 20,000 hours, and not for 1,000 hours like ordinary incandescent lamps. Also, LED modules consume much less electricity, and shine several times brighter than conventional lamps. You can purchase such LEDs in specialized stores. We bought a 100W LED module and decided to make a powerful flashlight for walking on dark winter evenings.
We will need
- - A small piece of sewer pipe with a bell, with a diameter of 110 mm. and about 250 mm long. and also a cap on a bell.
- - Lithium-ion batteries (Can be taken from old batteries from a laptop or phones).
- - Cooling radiator with fan (can be taken from the processor from the computer).
- - Controller for lithium-ion batteries YH11047A.
- -Increasing converter from 10-32 V to 12-35 V.
- -Lens for focusing the light flux.
- -100W LED LED Module.
- - Voltmeter with a sound signal.
- -Switches, buttons, etc ...
Making a powerful flashlight at 100 watts
Let's start with the LED module. Apply thermoplastic to the LED.
We install a cooling radiator, I use cooling from an old video card. We fasten the module on 4 sides with screws (if you do not have holes, they can be easily drilled and screwed in, they will make the thread themselves).
We cut off part of the plug from the socket of the same size as the cooling radiator. This will give us the opportunity to install a radiator with an LED in the pipe bell and tightly close the lid.
We make holes in the cover for the lens and mounting screws, as well as ventilation holes.
We install the lens in its place and fasten the screws with rubber washers.
To make it convenient to hold the lamp, we fasten the handle from the old cabinet.
The electrical part of the flashlight consists of modules. The main module YH11047A monitors the state of charge on the batteries, you can also use any other 4MS BMS instead. The voltage from the controller goes to a powerful 150W. boost converter. For convenience, so that you can adjust the brightness of the LED, replace the built-in tuning potentiometer with a large one, to fix it on the case. We connect an LED module to the output of the converter. To monitor the voltage on the batteries, we will use a voltmeter with an audible signal that will beep when the battery is low voltage.
We took the batteries from the old iPhone 5, 24pcs. which connected 6 pieces. in parallel to increase the capacity and sequentially with each other to increase the voltage, the assembly 4s6p was obtained. Batteries can also be taken from old laptop batteries.
We make holes for control buttons in the case: indicators, switches ...
We assemble the electrical modules in one node so that it is convenient to install everything in the housing. We isolate the modules and ensure that there is no short circuit anywhere.
Everything is assembled on the old case from the iPhone 6+, on the corners of which we screwed the modules with corners to the main pipe. We also install the control buttons and glue the connector for charging the flashlight with hot glue.
In the back, install the fan and fasten with ties. Air will cool the electrical modules, and the radiator of the LED, passing through the entire pipe. If possible, install protection on the fan blades ...
To better fix the LED, we fasten the radiator to the body on the sides.
Conclusion
During the test of the lantern, we got 2 glow modes: the first, as we planned with the lens, the beam of light shines far and brightly and easily illuminates the edges of trees, it also illuminates the ground from the 9th floor, the beam of light is more than 30m. When we turned on the flashlight without a lens, the whole area around us was lit up with diffused light like during the day, but in this case it shines not far, about 10 m. You also need to be careful so as not to blind anyone.
