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Lamp upgrade makes you a hot-head

[Cameron] decided to give his twenty-year-old headlamp a makeover. He uses it when he’s out for a run and wanted to have more light to see where he’s going, as well as a red tail light on the back. The stock design uses an incandescent bulb on the front of the head band, and a battery pack on the back. He managed to convert the device to output 700 lumens without major changes to the form factor of the unit.

The first change he decided on is to use a Cree XLamp which provides the 700 lumens of light by drawing about 9.5 Watts of power. Obviously the original battery pack isn’t going to do well under that kind of load, so he also sourced a 5000 mAh Lithium battery. A bit of circuit design and PCB layout gives him two driver chips for the four-element LED module, a charging circuit for the battery, and an ATtiny13 to drive the head lamp and flash the red LED tail light. See the blinky goodness in the video after the break.

That’s a lot of light, but we wonder if he experiences a warm forehead from the heat sink used to keep that LED package cool? [Read more...]