Sold/Expired Feeler - Programmable Hotwire Regulated Driver drop-in for D-M@g

[sylathnie]

Re: Feeler for D M@g Programmable Hotwire Driver

If you can make me a nice programmable driver for this monster. I would be in for a few. I would love to be able to step up to 12 cells and have regulated output and variable levels. Right now it's just for kicks but with a good driver it would be actually useful. I would be glad to learn whatever I needed to program it and to purchase the tools. I really like the idea of accessing the interface through the switch hole.
Would this open up the possibility of different switch types as well? (Reverse, forward, momentary only, lighted, knob etc)

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

I would be in for one or two - an 85 for sure.

Great!

I would like one for the 62138/64610 combination and one for either a 64623 or a 64655. All will be run with up to 8 Li-on. If you can't make the high power version, then I would take 2 for the 62138.

Is that 8 Li-Ion in series? Not sure if the 40V rated parts would handle that. Maybe.

I would like one for use with one of the 20 v. Osram bulbs using 8 x IMR18650s as a power source. So I would need the driver to convert 32 volts to 20 or 21.

Same comment, voltage may be pushing 40V FET a bit too hard, with the transients et al. Might work.

If you can make me a nice programmable driver for this monster. I would be in for a few. I would love to be able to step up to 12 cells and have regulated output and variable levels. Right now it's just for kicks but with a good driver it would be actually useful. I would be glad to learn whatever I needed to program it and to purchase the tools. I really like the idea of accessing the interface through the switch hole.
Would this open up the possibility of different switch types as well? (Reverse, forward, momentary only, lighted, knob etc)

Yes absolutely on the switch type. The switch is on a small PC board that plugs into the regulator board inside via the six pin programming plug. So the switch board can be fabricated in many ways as long as it mates with the regulator. There is less room than one would expect, however, in the vertical direction. But it can stick out of the light tube since it is installed after the regulator slides in. Waterproofing becomes one issue if it sticks out much and the stock M@g switch cover won't fit...

Again, not sure if the 40V parts would hold up here. Very iffy. Might be able to do a high voltage version, probably not the first run.

The problem here is that the inductive kickback from the bulb punches the voltage up above the battery voltage. So far we have not blown any FETs but it is possible. More analysis or testing will have to be done before we can raise the ratings above the present 25V battery voltage and 10A bulb current.

But the interest is registered.

Thanks, Alan

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

Sled Machining update:

Turned the front disc to both diameters (it has two), bored the wire hole and parted it off. It looks good though the parted surface is less pretty than the other very nice surfaces. It is useable. It still needs four holes drilled and countersunk and two holes drilled and tapped before it is complete.

The parts, tools and materials from McMaster arrived. They sure are quick.

-- Alan

 

[andygillis]

Re: Feeler for D M@g Programmable Hotwire Driver

I've been following this regulator thread, was very interesting to me as a young engineering student! I'll be down for 1 of the drivers if possible.

 

[LuxLuthor]

Re: Feeler for D M@g Programmable Hotwire Driver

The problem here is that the inductive kickback from the bulb punches the voltage up above the battery voltage. So far we have not blown any FETs but it is possible. More analysis or testing will have to be done before we can raise the ratings above the present 25V battery voltage and 10A bulb current.

That will handle all of the 100W bulbs, and even the overdriven 64458 90W bulb, so I think this will really meet most needs.

Sled Machining update:

Turned the front disc to both diameters (it has two), bored the wire hole and parted it off. It looks good though the parted surface is less pretty than the other very nice surfaces. It is useable. It still needs four holes drilled and countersunk and two holes drilled and tapped before it is complete.

Now I'm letting myself get excited.

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

That will handle all of the 100W bulbs, and even the overdriven 64458 90W bulb, so I think this will really meet most needs.
Now I'm letting myself get excited.

Thanx for the encouragement, Lux.

Tonite I took a different tact. After thinking about it today and chatting with some folks at work and doing some cost estimates at emachineshop.com I decided to try another billet M@gSled. At this moment I have a beautifully turned sled body lengthened to fit the existing PC board, now to do the milling. I hope I don't mess this one up. Back to the shop.

-- Alan

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

Thanx for the encouragement, Lux.

Tonite I took a different tact. After thinking about it today and chatting with some folks at work and doing some cost estimates at emachineshop.com I decided to try another billet M@gSled. At this moment I have a beautifully turned sled body lengthened to fit the existing PC board, now to do the milling. I hope I don't mess this one up. Back to the shop.

-- Alan

Success. Pictures beaming in now (via Eye-Fi).

-- Alan

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

Success. Pictures beaming in now (via Eye-Fi).

-- Alan

Turning complete. Forward end (will support bulb) toward lower right.

Mill in motion. I used my largest mill bit this time, it turns out to be just over the width required for the original board. The new board will be smaller and a different bit will be required. This took quite a long time taking shallow passes. This mill bit is very large for a mini-mill..

M@gSled Prototype (still some holes to drill/tap)

Regulator test fit, it does not fit since there is extra stuff on the bottom of this one. I will build up another PCB from the first batch for this prototype. The part has been left in the mill vise until I review the calculations and make sure the mill cut is complete.

-- Alan

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

Summary of interest so far:

... So probably one, maybe more...

I am looking for 1 or 2 regulated mag D switches.
Philips 5761 needing 7,2 volt at 5,6 amps on 6 NIMH D-cells or 7 NIMH D-cells (yes 7D) or a mag 623

I expect I'll be in for at least a couple..
I'll want to run the usual lamps, on A123 power sources.
...

... at least 3-5 (likely more) from you and also from Jimmy. I have the programmer, and would use them in a variety of WA, Philips 5761, & Osram varieties. I'm comfortable doing the programming with dongle...

... I'm interested in at least 'one' to start off with...

I'd like one running a Wa1111 with 3 x 17670...

I would be in for one or two - an 85 for sure.

I would like one for the 62138/64610 combination and one for either a 64623 or a 64655. All will be run with up to 8 Li-on. If you can't make the high power version, then I would take 2 for the 62138.

I would like one for use with one of the 20 v. Osram bulbs using 8 x IMR18650s as a power source. So I would need the driver to convert 32 volts to 20 or 21.

If you can make me a nice programmable driver for this monster. I would be in for a few. I would love to be able to step up to 12 cells and have regulated output and variable levels. Right now it's just for kicks but with a good driver it would be actually useful. I would be glad to learn whatever I needed to program it and to purchase the tools. I really like the idea of accessing the interface through the switch hole...

I've been following this regulator thread, was very interesting to me as a young engineering student! I'll be down for 1 of the drivers if possible.

Approx 15-20 so far. Roughly.

Thanks,

-- Alan

 

[jasonck08]

Re: Feeler for D M@g Programmable Hotwire Driver

Are you going to integrate a bi-pin socket?

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

Are you going to integrate a bi-pin socket?

Yes. My plan is to use standoffs or internally threaded tubes to a ceramic bipin socket so the socket height can be adjusted. They would be included.

-- Alan

 

[LuxLuthor]

Re: Feeler for D M@g Programmable Hotwire Driver

Alan, I guarantee that most people still don't realize the significance of this (including Jimmy's and wquiles) because the development threads were so technical. This series of developments is by far the most exciting news for incans in the last few years.

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

Alan, I guarantee that most people still don't realize the significance of this (including Jimmy's and wquiles) because the development threads were so technical. This series of developments is by far the most exciting news for incans in the last few years.

I probably didn't help by making the first post in this thread so long and technical as well.

Tomorrow I have some other things to do, but I'm going to try and wedge in building up another Regulator PCB for the prototype, and get the holes drilled and tapped. Maybe get the prototype working. I went through the numbers again tonite and ended up taking another .038 off the Sled so the board will have more clearance underneath. That reminds me I need to make the brass adapter block to bring the battery plus to the pc board as well. I think I need another tap for the cone screw in the bottom. A few details, but this prototype is really getting close. I would really like it to be ready to take to the San Jose CPF gathering next weekend.

-- Alan

 

[jasonck08]

Re: Feeler for D M@g Programmable Hotwire Driver

Alan, I guarantee that most people still don't realize the significance of this (including Jimmy's and wquiles) because the development threads were so technical. This series of developments is by far the most exciting news for incans in the last few years.

The price is not so exciting. If only it was going to be in my pricerange... I'll probably never get my hands on something like this.... :mecry:

 

[sylathnie]

Re: Feeler for D M@g Programmable Hotwire Driver

If the driver is under $100 it will be a great value. There is alot of blood, sweat and tears in a project like this. After attempting a few of my own builds that duplicate what others have sold I am usually convinced that the cost of buying the item is justified. Some times the journey is part of the fun though. I'm grateful that he is willing to share the results of his journey. :thumbsup:

 

[Starlight]

Re: Feeler for D M@g Programmable Hotwire Driver

AW's switch is a 3 level with soft start. It sells for $75 and is selling very well. This switch from Alan B is infinitely variable, soft start, has a higher amp rating, allows much higher rated battery packs for longer runtime, has adjustable voltage output, has adjustable shutoff voltage to protect your batteries, and is programmable for things like strobe, etc. It is a steal at $100+.

 

[Alan B]

Re: Feeler for D M@g Programmable Hotwire Driver

First, I want to thank everyone for their comments here. It is probably premature to get too deep into pricing discussions at this point. Today I spent quite a few hours re-arranging the production PCB to incorporate an improved positive terminal. I had to move a lot of parts and rewire part of the PC board, and there is a lot more fine tuning to get the physical dimensions exactly right to mesh with the M@g body and the aluminum sled. It is just amazing how much time it takes to get all this stuff to line up. This looks like a simple project but it has electronics, mechanical and software components that all have dozens to hundreds of parameters.

I think the way this will shake out is there will be two choices for the D M@g. The M@gSled here and JimmyM's. By all indications JimmyM's will be less expensive. It will not be as easy to install or program since it will be mounted inside the KIU base and will require hacking the M@g switch. This M@gSled will be a drop-in. So there will probably be choices at different price points that make sense.

We don't have a good cost estimate for the M@gSled yet because the design is still evolving slightly, and there are some complicated mechanical parts involved that have considerable costs in small quantities. So I don't really know yet what all the costs are going to be. It looks like we might be able to make 50 of them in the first production batch. That is a pretty small quantity. Also it looks like each one is going to be somewhat individually programmed. That is time consuming. Perhaps there can be a discount for choosing standardized programming from a menu. Many details to work out yet.

-- Alan

 

[LuxLuthor]

Re: Feeler for D M@g Programmable Hotwire Driver

jasonck08, no price has even been discussed...so not seeing why you made that comment this early.

Alan that all sounds like what I expected. I think 50 is a good estimate, and I am 100% sure those will all be sold. Are you going to preserve the ability for people to do their own AVR 'fiddling' ? If it helps, lock me in for 5 of them.

 

[jasonck08]

Re: Feeler for D M@g Programmable Hotwire Driver

Lux, in the first post he said target was under $100. So I assumed it would be around that price… For me, that's too much, but for others that might be a "steal." It looks like a lot of work is going into these though, and the profits will be well deserved! Best of luck on finishing up this awesome project!

 

[LuxLuthor]

Re: Feeler for D M@g Programmable Hotwire Driver

Lux, in the first post he said target was under $100. So I assumed it would be around that price… For me, that's too much, but for others that might be a "steal." It looks like a lot of work is going into these though, and the profits will be well deserved! Best of luck on finishing up this awesome project!

Fair enough! I missed that in his long opening post!