LED flashlight with 500 LEDs

The LED flashlight today does not surprise anyone. They can be bought at almost every corner. Varieties of all shapes and sizes in our market are innumerable. But their characteristics are very different, and sometimes do not correspond to the stated. All the blame for the cheapening of LED products, and at the same time, its quality. And the more interesting is the homemade thing that we want to present to you today. It was made by the author 10 years ago, and, as he himself admits, can be modernized to reflect modern components. However, the original model works properly and pleases its owner with a quite powerful and long-lasting glow. What is so special about her? Let's look together.
LED flashlight of 500 LEDs

Device Specification

  • 513 LEDs 5 mm (a series of three) li>
  • Lead-acid battery 12 V / 7 Ah;
The LED panel is assembled on a conventional prototyping board, with a consistent soldering of all elements.It is possible to fit it in shape with the help of a hacksaw, paint knife or grinder. The disc diameter is 13 cm.
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
The device controller used mechanical DC relays 892-1Cc-C 12V 5A DC, resistance and transistors. You can use sewer pipes and fittings as a housing.
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
Characteristics of the device (at full power)
  • The value of the light flux is 3500 - 4000 lumens; br>
  • Charging the battery for 10 minutes;
  • Power consumption 53 W(including the power consumption of a 3 W resistor).
Features of controls
  • Various brightness settings achieved by supplying different number of LEDs;
  • Safety voltage switch to prevent the lead-acid battery from discharging;
  • The ability to recharge the battery without removing it from the case.

Assembly specifications

Turn on / off and protection

The first switch activates the “system / charger” mode. Here we can choose to use the battery to recharge it or to operate the flashlight. When the device is charging, the lamp is completely disconnected by means of a six-contact switch. In the recharging mode, you can activate the operation of the flashlight by the "on / off" switch. On the back panel are several LEDs. The first green LED lights up when there is power in the flashlight system. Thus, the “system / charger” switch is switched to the “system” mode, and the “on / off” switch is set to the “on” position. But the LED panel is not yet operational. A safety module is provided to protect the lead-acid battery from over-discharge.The automatic voltage switching circuit is responsible for this, and the second green LED under the inscription “safety ok” signals. When it lights up it means that everything is in order and the voltage is normal, i.e. above the minimum. There are three buttons for the protection system:
  • №1 The green “safety on / off” button activates the protection system;
  • No. 2 The black button (below the green) - turns off the protection system;
  • No. 3 Black “override” switch - power override.
When protection is activated, the front LEDs go out and the voltage drops to a certain face value. If it reaches the minimum, the protection system will stop. You can start it again by holding the green button. A low charge will be indicated by a red “low voltage” LED. When the third button-switch is activated, power is applied, bypassing the protection system, and the lamp can be used even at low voltage. But the discharge of the battery will now have to be controlled manually. When the switch is active, both the "safety ok" and "low voltage" indicators still work. Overriding can be convenient if your battery is not fully charged, but there is enough charge left in it.In case you use all the LEDs (“phase 3”), due to leakage to the battery, the voltage drops by about 1 volt. Thus, protection can be active in standby mode, but it will turn off when used. And when the switch is active, you can notice how the protection turns on and off without loss for the LEDs. When you use the lamp at full power, check the protection activity after turning off the LEDs for a couple of seconds. If the protection is not activated even after turning off all the LEDs, it means that the battery charge is too low and is not suitable for its safe use. When using the flashlight for a long time in “phase 1” (3 LEDs) or “phase 2” (100 LEDs) modes, it is recommended not to use override, as you can easily forget to turn off the flashlight in time. When power is supplied to the LED switches , the third LED on the “led system on” panel will light up. In the photo we can see that the override switch is active (the fourth yellow override LED is on). At the same time, the voltage is below the minimum value, because the safety ok LED is off and the low voltage LED is lit in red. Please note that the black safety off button will not work if the override switch is active.Thus, the voltage monitoring circuit will always display the battery charge status. 03 / medium / 1521307557_11.jpg "style =" max-width: 100%; " alt="LED flashlight of 500 LEDs">

Various brightness settings

The lamp has three different brightness settings for the LEDs. They are marked with “phase 1”, “phase 2” and “phase 3” switches. Mode «phase 1» implies the illumination of all three LEDs. The work of the flashlight becomes very long, it can last more than one day on one charge, but it shines like an ordinary inexpensive LED flashlight on AA batteries. The “phase 2” mode includes 100 LEDs, and the “phase 3” - the entire platform. Modes are switched by the corresponding buttons on the panel, and they can be used both individually and in various combinations. When the “phase 3” mode is on, the other modes remain activated. These adjustments are possible due to the presence in the relay circuit. Opposite each of the fixed mode switches, there are buttons for momentary activation, duplicating these modes. By alternating the positions of the switches and buttons, individual combinations of LED activity can be used.For example, to transmit Morse code signals, or to check the connection with a group in a hike by pressing the "phase 3" button when the "phase 1" or "phase 2" modes are on. And if you just need to consider something better in the dark, the buttons for short-term activation of the mode are what you need!
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs

Optional external device

Complete the control panel with elements intended for an external device. To make the flashlight more versatile, the author added a fourth switch of the "phase" type and a button next to which is a socket for the "ext output" connector of the charger. With this button you can turn on and off the 12V output on this connector for connecting an external device. The “charger / system” switch must be in the “charger” mode to ensure that the battery is disconnected from its system. The device can be connected from any DC source to 12V. According to the author, even a small 9V battery can ignite this flashlight, but not at full capacity.You can also use an auto-cigarette lighter to charge or work it, since the battery of the flashlight produces only 7Ah current, while the car battery can produce up to 100 Ah.
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs
LED flashlight of 500 LEDs

Conclusion

For those who find this model of a LED lamp too complicated, modern analogs of similar assemblies based on LED arrays will do. Their power reaches 100W, the luminescence temperature is 6-10 thousand kW, and the light wavelength is up to 9000 Lm. Brightness from such lamps, even without a reflector and a concentrator is very large, and the dimensions are not large. Nevertheless, the benefits are obvious, because the soldering of 500 LED elements is not an easy task. Instead of lead-acid batteries, you can also use lithium or polymer-lithium smaller and more powerful. Otherwise, this flashlight is quite powerful and bright, and according to its characteristics, fans of handicrafts with their own hands deserve the attention.

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