Own The Night With This Ludicrously Bright DIY Flashlight

November 8, 2021 by Dan Maloney 27 Comments

If you’re a flashlight person, you know that there’s little you would do to get the brightest, most powerful, most ridiculous flashlight possible. You might even decide to build yourself a ludicrously powerful flashlight, like [Maciej Nowak] did.

If you choose the DIY route, be warned that it’s probably not going to be a simple process, at least if you follow [Maciej]’s lead. His flashlight is machined out of aluminum rounds, all turned down on the lathe to form the head of the flashlight. The head is made from three parts, each of which acts as a heat sink for the five 20-Watt CREE XHP70 LED modules. The LEDs are mounted with care to thermal considerations, and wired in series to DC-DC converter that provides the necessary 30 V using a battery pack made from four 21700 Li-ion cells. The electronics, which also includes a BMS for charging the battery and a MOSFET switching module, form a tidy package that fits into the aluminum handle.

The video below shows that the flashlight is remarkably bright, with a nice, even field with no hotspots. Given the 45-minute useful life and the three-hour recharge time, it might have been nice to make it so anywhere from one to five of the LEDs could be turned on at once. Some interesting effects might be had from switching the LEDs on sequentially, too.

Given the proclivities of our community, it’s no surprise that this is hardly the first powerful flashlight we’ve seen. This one broke the 100-Watt barrier with a single COB LED, while this ammo-can version sports an even higher light output. Neither of them looks much like a traditional flashlight, though, which is where [Maciej]’s build has the edge.

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Big RGB LED Cube You Can Build Too

November 4, 2021 by Dave Rowntree 35 Comments

LED cubes are really nothing new, many of us consider the building of a good sized one almost an electronics rite of passage that not so many manage to find the time or have the skill to pull off. It’s our pleasure to draw your attention to a lovely build, showing all the processes involved, the problems and the solutions found along the way.

Building a small cube is somewhat of a trivial affair, especially without considering PWM colour mixing, however as simple maths will illustrate, as you increase the number of LEDs on each side, the total number will quickly get quite large. More LEDs need more power and increase control complexity considerably. A larger matrix like this 16 x 16 x 16 LED build, has a total of 4096. This would be a nightmare to drive with plain RGB LEDs, even with cunning multiplexing, but luckily you can buy indexable LEDs in a through-hole package similar to the ubiquitous WS2812-based SMT LEDs you see around. These are based on the PD9823 controller, which can be programmed as if they were a WS2812, at least according to this analysis. Now you can simply chain a column of LEDs, with the control signal passed from LED to nearest neighbour.

Early on in the video build log, you will note there are four power supply modules needed to feed this juice. If we assume each LED consumes 60 mA on full-white (the data for this product link shows a peak value of 100 mA) that is still a total of 246 A or around 1 kW of power. The video does shows a peak power measurement of around this figure, for the whole array on full white, so the maths seems about right.

Control is via a Teensy 4.0 using the FlexIO function of the IMXRT1060RM CPU, and a bunch of 74AHCT595 shift registers giving 32 channels of up to 1000 LEDs per channel if needed. Roughly speaking, using the DMA with FlexIO, the Teensy can drive up to 1 Million LED updates per second, which works out about 32 channels of 100 LEDs per channel updated at 330 frames/sec, so plenty of resource is available. All this is with almost no CPU intervention, freeing that up for handling the 2.4-inch LCD based UI and running the animations, which looks pretty darn slick if you ask us. You can checkout the description of the firmware in the firmware section of the GitHub project. 3D printed jigs allowed for bending and clipping the LEDs leads as well as fixing and aligning the LED column units, so there really is enough detail there to allow anyone so inclined reproduce this, so long as you can swallow the cost of all those LEDs.

For a different approach to LED cubes, checkout this sweet panel based approach, and here’s a really small 4x4x4 module for those with less space to spare.

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Sign Detects RF To Show You Are On The Air

October 19, 2021 by Al Williams 2 Comments

Like a lot of hams, [Stuart] wanted an “on the air” sign. These signs often connect to a PTT switch or maybe an output from the transmitter that also does things like switches antennas or switches in an amplifier. [Stuart’s] version, though, simply senses the radio frequency emissions from the transmitter and lights up that way. You can see two videos about the sign, below.

Honestly, we are a little worried that he might have too much RF at his operating position. Presumably, the device is pretty sensitive, especially if there’s any actual antenna on the sign. A comparator and a pot let you set the sensitivity so it doesn’t light up when your garage door opens.

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Learn DMX512 Basics

October 15, 2021 by Al Williams 11 Comments

If you’ve done anything with modern lighting effects, you’ve probably heard of DMX, also known as DMX512. Ever wonder what’s really happening under the hood? If so, then you should have a look at [EEForEveryone’s] video on the topic, which you can see below.

At the core, the DMX512 uses RS485, but adds software layers and features. The video uses the OSI model to show how the system works.

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LED Matrix Hourglass Knows Which Way Is Up

October 8, 2021 by Donald Papp 6 Comments

[Fearless Night]’s slick dual hourglass doesn’t just simulate sand with LEDs, it also emulates the effects of gravity on those simulated particles and offers a few different mode options.

The unit uses an Arduino (with ATMEGA328P) and an MPU-6050 accelerometer breakout board to sense orientation and movement, and the rest is just a matter of software. Both the Arduino and the MPU-6050 board are readily available and not particularly expensive, and the LED matrix displays are just 8×8 arrays of red/green LEDs, each driven by a HT16K33 LED controller IC.

The enclosure and stand are both 3D-printed, and a PCB not only mounts the components but also serves as a top cover, with the silkscreen layer of the PCB making for some handy labels. It’s a clever way to make the PCB pull double-duty, which is a technique [Fearless Night] also used on their earlier optical theremin design.

Those looking to make one of their own will find all the design files and source code handily available from the project page. It might not be able to tell time in the classical sense, but seeing the hourglass displays react to the device’s orientation is a really neat effect.

Exploring An Aftermarket LED Headlight Retrofit Kit

September 23, 2021 by Tom Nardi 30 Comments

There’s plenty of debate about drop-in LED headlight bulbs, especially when they’re used with older reflector housings that were designed for halogen bulbs. Whether or not you personally feel the ultra-bright lights are a nuisance, or even dangerous, one thing we can all agree on is that they’re clearly the result of some impressive engineering.

Which is why we were fascinated to see the teardown [TechChick] did on a “Ultra 2 LED” retrofit from GTR Lighting. Apparently one of the diodes was failing, and as part of the warranty replacement process, she was informed she had to make it completely inoperable. Sounds like a teardown dream come true. If a manufacturer ever told us we needed to take something apart with extreme prejudice and provide photographic evidence that the deed was done, we’d be all too happy to oblige.

The driver itself ended up being completely filled with potting compound, so she doesn’t spend much time there. Some will no doubt be annoyed that [TechChick] didn’t break out the small pointy implements and dig all that compound out, but we all pretty much know what to expect when it comes to driving LEDs. The real interesting bit is the bulb itself.

As is common with these high-output automotive LEDs, the Ultra 2 is actively cooled with a small fan that’s actually enclosed within the heatsink. With the fan and the two-piece heatsink removed, she’s able to access the LED module itself. Here, two PCBs are sandwiched back to back with a hollow copper chamber that leads out of the rear of the module. When [TechChick] cut into the copper she said she heard a hiss, and assumed it was some kind of liquid cooling device. Specifically we think it’s a vapor chamber that’s being used to pull heat away from the diodes and into the heatsink at the rear of the module, which speaks to the advanced technology that makes these bulbs possible.

While laser headlights are arguably the future of automotive lighting, it’s going to be quite some time before they trickle down to those of us that don’t own supercars. Until then, when used responsibly, these LED retrofits can inject a bit of cutting-edge tech into your old beater without breaking the bank.

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Bringing The Quake Flicker To Life With A Hacked Light

September 21, 2021 by Tom Nardi 14 Comments

If you ever feel a pang of shame because you’ve been reusing the same snippets of code in your projects for years, don’t. Even the big names do it, as evidenced by the fact that code written to govern flickering lights back in 1996 for Quake is still being used in AAA titles like 2020’s Half-Life: Alyx. In honor of this iconic example of digital buck-passing, [Rodrigo Feliciano] thought he’d port the code in question over to the Arduino and recreate the effect in real-life.

Since the Quake engine has been released under the GPLv2, it’s easy to pull up the relevant section of the code to see how the lighting was configured. Interestingly, lighting patterns were implemented as strings, where the letters from a to z referenced how bright the light should appear. So for example, a strobe light that goes between minimum and maximum brightness would be written as “aaaaaaaazzzzzzzz”, while a flickering light could be represented with the string “nmonqnmomnmomomno“.

An emergency light provided the LEDs and enclosure.

This ended up being very easy to implement on the Arduino in just a few lines, as [Rodrigo] simply had to assign each letter in the string a numerical value between 0 and 255 using map, and then use the resulting number to set the LED brightness with analogWrite.

With the code written, [Rodrigo] then had to put the hardware together. He stripped down a basic emergency light to get an array of white LEDs and a handy enclosure. He also wired up a simple transistor circuit on a scrap of perfboard so the Arduino Pro Mini could control all the LEDs from a single GPIO pin. Combined with a long USB cable to power it, and he’s got a perfect desk accessory for late-night gaming sessions.

In the video below you can see the final result, which [Rodrigo] has even synced up to footage from the classic 1996 shooter. The light makes for an interesting conversation piece, but we think the logical next step is to work this technique into an ambilight-like system to really make it feel like you’re wandering down those dimly lit corridors.

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