Maglite Forever Fashlight Poll

[ama230]

Hello gals and guys,

I am an electrical engineer from A.S.U. in Arizona that has tons of experience with alternative energy technologies and was going to see if there are some potential customers on my custom light. I have one built right now as this was a senior project and has turned out better than anticipated. I had made this custom light to make and advance smart charger for the caps that was run by a microcontroller to tell the stages of charge by led indication. But that was an expensive one-of. This light just uses a basic charger that is still awesome but you have to go by time(10min) rather than the expensive charger that I made but could make another one if wanted but this works just as well but is a little slower as the charger runs at 6v@300mA. I can get these cheap at fry's so that's why I use them and also they come with all types of plugs and you can vary the voltage as well(reverse polarity, the whole bit)

First off the power plant will be two ultracaps@700F Maxwell so they are the best ones available....

Second will be a 600plus lumen light engine....
This is 36 Nichia GS k1's @ 40000Mcd(Newest and Brightest Bin guaranteed!!!)

Third will be the charger and misc hardware....
This will be the charger and connector put in the tail of the light.(3.5mm Headphone jack recessed so its flush with the cap, so it can still tail stand.)Other variations are up for discussion and use. Then wiring and other components. You can choose a car charger or home or both.

Performance:It slowly decreases as the cells are dumping the electrons. Ultracaps have about the same power density as a AA battery, just in a bigger form factor. Everything on this light is environmentally safe and could be 100% recycled.

800lumens @ 30+ minutes @ 5.4v

400Lumens @ 30+ minutes @ 2.7v

Charge time is 10minutes, could be faster but they cost more if wanted. Could be as little as 2min.

Never have to take the light apart to change or fix anything for 500K cycles.(1 cycle = 1charge and 1 Discharge)

Lighter than a D-cell@10ounces vs. 25ounces with regular or rechargeable batteries.

Do not need to adjust head as this thing rocks. Focusing is not needed on this light so that adds to the simplicity.

No thermal management problems as the light stays cooler than your hand as the led array sits in the head with great contact. The head is screwed all the way in for maximum strength and durability and never needs to be adjusted.

It will come ready to run and the option is up for using your own 2dcell light or 3cell(cost a little more for an extra ultracap) and more if requested.

Cost will be in the hundred dollar range +/-10 bucks. 80+/-bucks if it's your own light. I would love to see the machined ones that have grooves in it as this would be the ultimate ultimate mag lite.


Anybody that would like this done let me know or even if this would be of interest on here as this is far from mainstream. This is also something that does not heat up the light as the head and light assembly are in perfect harmony. Service men (Cops, firemen and military) could still use this as a weapon as it still is solid and will not break. Not temperature effect as the extremes do not harm the caps.

So let me know if this is of interest to you guys and gals...

This will meet and exceed expectations as this will never need to be maintained or replaced for at least the 10k hrs of the led's. Show some love for the affordable light saber. As I can guarantee everything on this light as i will replace anything that goes wrong.

Disclaimer:
All sourced items are from the highest quality and when putting it together there is only the finest quality. This could be a perfect, one of light that no one will have or will get. I am here to stay and hope I can get the credit or props around here starting with this build as I can divert my abilities and get the opportunity to do such a great alternative project. Heck you can mount this to a dune buggy or sand rail or off road truck and will do better than any KC light(without the mosquitoes...)

I have extensive knowledge in thermoelectric devices and advanced power storage systems and led lighting so there will be no quality control problems. I have 10 years experience with five in the field and this is not my first project. AC/DC systems are first knowledge so this is no prank. I am not trying to be cocky but I wanted to let you know what my experience is.

Thanks a lot for your interest as all comments and questions are welcome...
Eric Ramirez

 

[kramer5150]

22.2 Lumens from each Nichia... how reliable are they when driven that hard, and how stable is the color tint?

Got any pics?:thumbsup:

 

[ama230]

Here is a pick of the 48led module that is really doing 800+lumens and is working off 18v but the maglite is a smidge less bright. As you can see the tint is pure white with no artifacts with lots of spill. I will be doing a review of the maglite one in the next day but this gives you a good idea of output.

Oh yeah also the beam on the right is a maglite xl100 with a cool beam from the rebel 090 with three tenergy AAA's @ 1000mah(85lumens). Then the right is the icon 2 rogue with a cree that is rather warm with two tenergy 2600mah AA's(100lumens).

The nichias are good for 10000hrs and they are not going to fade if driven a little more than 15lumens. Testers on here have proven that. Then the tint is pure white as i have not seen a light with this quality of beam.

Hope this helps, oh yeah also to compare this thing is equal if not more to two headlights on a vehicle and good headlights. Let me know if there are any more questions or comments as i will get back to you. Hope you like the pics as these were with not any night exposure or any trickery.
http://i932.photobucket.com/albums/ad164/ktm230/8-18v nichia k1 48 led module/IMAG0145.jpg

 

[Jash]

Don't want to burst your bubble or anything, but there are a few guys here who know how to make a thumping good mag drop-in.

http://www.candlepowerforums.com/vb/showthread.php?t=252279

 

[Norm]

Don't want to burst your bubble or anything, but there are a few guys here who know how to make a thumping good mag drop-in.

I think what Eric is offering falls into an entirely different category, I for one am very interested.
Norm

 

[LEDninja]

The 5.11 Tactical costs $169.99 at lapolicegear.
I believe it uses similar technology.

-

My concern is the use of 5 mm arrays. 5 mm LEDs have an insulating air bubble in front of the LED die and another one behind. This traps the heat in the LED which kills it. Arrays are worse as instead of cooling air around it, there are a bunch of equally hot LEDs.
Nichia tests their LEDs singly in a controlled environment (I read that as a nice cool 20°C-25°C). Flashlights get used in hot summer nights. With most of the inside LEDs in an array not able to dump heat to the rather warm air they just burn out.
For 800 lumens you will have to get rid of 10 watts of heat. If the flashlight body or head does not get hot that means the heat is trapped inside cooking the LEDs.
There have been many reports on CPF of 5 mm arrays in both flashlights and fixed lighting bulbs burning out in 2-3 weeks instead of the claimed 100000 hours. As a result most CPF members just don't trust 5 mm arrays.
That is probably why Jash linked to a thread that uses MC-E LEDs. The power LED dies are connected directly to its backplate which is attached to a heatsink connecting the LED to the flashlight body. Heat gets sucked away to the flashlight body and dumped into the surrounding air fast.

-

My other concern is the runtime. If I dropped something under my desk I reach for the 1AA flashlight in my pocket. If I go for a walk in the woods, I'd want more than 30 minutes. My walk with the Toronto GTA CPF members took 1-1/2 hours. Custom flashlight maker Elektrolumens claims LEOs always ask for 2 hours minimum runtime.
Think you have a typo
800lumens @ 30+ minutes
400Lumens @ 30+ minutes
Same runtime for both outputs?

 

[netprince]

This would be great in a mag-charger, which would always leave it charged and ready to go...

Also, use a cree xpg or phlatlight sst50, and it would be awesome.

Or perhaps just provide the powerplant as a kit and allow us to build the rest of the light?

This does sound like a neat idea, I hope it gets built. I may still be interested in the current design once more runtime/beamshots/specs are provided.

 

[ama230]

Don't want to burst your bubble or anything, but there are a few guys here who know how to make a thumping good mag drop-in.

http://www.candlepowerforums.com/vb/showthread.php?t=252279

i am not using a power led drop in because everyone has one. If you read my description of what i am building this in no way is the same. MINE IS COMPLETELY DIFFERENT. Try reading before you post, please.

Thank you

 

[kramer5150]

I think many people missed this keypoint...

"First off the power plant will be two ultracaps@700F Maxwell so they are the best ones available...."

interesting...:thumbsup:

http://www.mouser.com/Search/Refine.aspx?Keyword=MAXWELL+capacitor&No=25&FS=True

Please do post more pictures Eric. I think a ~10 minute charge time would appeal to many.

 

[ama230]

The 5.11 Tactical costs $169.99 at lapolicegear.
I believe it uses similar technology.

-

My concern is the use of 5 mm arrays. 5 mm LEDs have an insulating air bubble in front of the LED die and another one behind. This traps the heat in the LED which kills it. Arrays are worse as instead of cooling air around it, there are a bunch of equally hot LEDs.
Nichia tests their LEDs singly in a controlled environment (I read that as a nice cool 20°C-25°C). Flashlights get used in hot summer nights. With most of the inside LEDs in an array not able to dump heat to the rather warm air they just burn out.
For 800 lumens you will have to get rid of 10 watts of heat. If the flashlight body or head does not get hot that means the heat is trapped inside cooking the LEDs.
There have been many reports on CPF of 5 mm arrays in both flashlights and fixed lighting bulbs burning out in 2-3 weeks instead of the claimed 100000 hours. As a result most CPF members just don't trust 5 mm arrays.
That is probably why Jash linked to a thread that uses MC-E LEDs. The power LED dies are connected directly to its backplate which is attached to a heatsink connecting the LED to the flashlight body. Heat gets sucked away to the flashlight body and dumped into the surrounding air fast.

-

My other concern is the runtime. If I dropped something under my desk I reach for the 1AA flashlight in my pocket. If I go for a walk in the woods, I'd want more than 30 minutes. My walk with the Toronto GTA CPF members took 1-1/2 hours. Custom flashlight maker Elektrolumens claims LEOs always ask for 2 hours minimum runtime.
Think you have a typo
800lumens @ 30+ minutes
400Lumens @ 30+ minutes
Same runtime for both outputs?

As i said as this thing does not get hot as the head and led unit are touching so thermal management is not a problem. Are you just skimming through the post to bash it or what. I am a professional that knows what's going on and this is not a superglue and duct tape project. From what I see is that you DO NOT understand what i am doing so please move on to another thread.

This does use the same technology 5.11 is using without a fancy charger as it does not require one. The outputs are because of the light are going from 6v to .7v, as the brightness will fade with depleting power. I do not use google to get my knowledge as I mess with this stuff everyday and this is my profession(HINT: I AM AN ELECTRICAL ENGINEER). The light falls to a minimum of 400lumens so this thing does not get dim. It goes through different stages as this is not a form of chemical reaction, think of a storage tank(for water) with a small hole in it. The electrons are just let go to whatever the load is.

Please in future posts i am looking for comments and questions rather than this thing CAN NOT do this and that. I have tested it in and out and there is NOTHING WRONG. Others in the past of course have no experience or knowledge of what they are doing and PLEASE do not compare me to them as I AM A PROFESSIONAL not an amateur. My post is all facts and no gimmick.

Also why doesn't a photon freedom get hot then. I guess the plastic is the heat sink and will burn up in a couple of days. Photon should check into it as I do not think they know what they are doing. COME ON..... GET REAL.:poke:

If this isn't of interest then.....
Please move on to another post.....:thumbsup:

 

[ama230]

This would be great in a mag-charger, which would always leave it charged and ready to go...

Also, use a cree xpg or phlatlight sst50, and it would be awesome.

Or perhaps just provide the powerplant as a kit and allow us to build the rest of the light?

This does sound like a neat idea, I hope it gets built. I may still be interested in the current design once more runtime/beamshots/specs are provided.

I am not going to use a power led as I am doing something completely different. The kit thing seems like a great idea and for liability reasons, these need to be handled with care when assembled. I do not think 5.11 is going to a DIY kit as this is a rather new technology even though its been around for 20+ years.

I will be posting pics of it when it get dark tonight so you can see whats going on. Thanks for your interest and constructive comments.:D

 

[ama230]

I think many people missed this keypoint...

"First off the power plant will be two ultracaps@700F Maxwell so they are the best ones available...."

interesting...:thumbsup:

http://www.mouser.com/Search/Refine.aspx?Keyword=MAXWELL+capacitor&No=25&FS=True

Please do post more pictures Eric. I think a ~10 minute charge time would appeal to many.

The place where i source my materials is not mouser. But still is a good find thanks for pointing that out. I will be doing a extensive review of specs/ beam shots and run time. Thanks for your interest as I aim to please and maybe blow your mind...:rolleyes:

 

[Simon520]

How about posting some pics and stats of the power source?

 

[ama230]

How about posting some pics and stats of the power source?

If i show you id have to kill you... just kidding:p. I will post pics tonight. Thanks for your interest.

 

[Jash]

i am not using a power led drop in because everyone has one. If you read my discription of what i am building this in now way is the same. MINE IS COMPLETELY DIFFERENT. Try reading before you post, please.

Thank you

I read your post several times as I couldn't actually believe what I was reading. You want people to fork out close to $100 for a light that has declining output, poor tuntime and requires high maintenance (needs charging every 30 minutes).
Don't assume that everyone who questions your design is stupid. That's arrogant and will win you no support.

Don't get me wrong, I believe you know what you're doing. It's just that here on CPF, people generally want the most reliable output along with the most runtime in a package that is both simple and tough.

There are probably situations where your light is an effective tool, but there are also lights that would serve that purpose equally if not better,
eg. http://www.batteryjunction.com/terralux-tle-300-mr-ex.html


FWIW, I got a 4D mag with a SSC P7 that pumps 400otf lumens for about two hours and takes 90 mins to charge. I built it myself and cost about $100 including batteries and charger.

Good luck with your project though. Who knows, with a little more development you could end up being one of the sought after modders. It's early days.

 

[DM51]

ama230... your post #10 above is quite astonishingly intemperate, rude, and uncalled for.

You need to show more respect to others. If you are going to fly off the handle whenever someone questions you, you will not last long here.

Please edit that post to tone it down and remove the rude and abrasive comments.

 

[ama230]

I read your post several times as I couldn't actually believe what I was reading. You want people to fork out close to $100 for a light that has declining output, poor run time and requires high maintenance (needs charging every 30 minutes).
Don't assume that everyone who questions your design is stupid. That's arrogant and will win you no support.

Don't get me wrong, I believe you know what you're doing. It's just that here on CPF, people generally want the most reliable output along with the most run time in a package that is both simple and tough.

There are probably situations where your light is an effective tool, but there are also lights that would serve that purpose equally if not better,
eg. http://www.batteryjunction.com/terralux-tle-300-mr-ex.html


FWIW, I got a 4D mag with a SSC P7 that pumps 400otf lumens for about two hours and takes 90 mins to charge. I built it myself and cost about $100 including batteries and charger.

Good luck with your project though. Who knows, with a little m ore development you could end up being one of the sought after modders. It's early days.

I can guaranteed that the tint of my light has better quality with no artifacts and is 100% pure white light. There is not going to be a light out there that can beat the color of the nichia gs k1. I do not think that 50% of the market uses nichia for no reason. There is no power led so there is no cool tint or warm tint,its just crazy white.:eek:

This does not have any fancy modes and still uses to super reliable UI of the maglite. If the light was designed for 600+lumens then it would run just shy of 400lumens when it goes below the .7v of the Vf. But this is a little more output then it will go to 400lumens before going lower than the Vf of a diode.

I understand that the run time is poor but then again the 50-60lumens that i had it originally had it for, lasted 8hrs but it was very dim and thought this was impractical.

High performance, safety and reliability was the design i was going for. there are thousands of people that have the same light you have and that was what i was not going for because anybody can do it and its not really anything special. I can get the parts from Deal extreme and make the same light you have for fifty bucks including the cost of the maglite. Then again this requires you to disassemble the light and this again was what i was not going for.

This is a buy, use, recharge,use, recharge for 500k cycles and leave it alone light. Also you can still use this as a hammer when you are stuck in the desert with a broke down vehicle. You can not break it unless you take it apart. As when this is put together, dis assembly is not required.

As with all technologies you have to make some sacrifices(give and take). I thought i made the best of what I am using. :twothumbs

 

[ama230]

This would be great in a mag-charger, which would always leave it charged and ready to go...

Also, use a cree xpg or phlatlight sst50, and it would be awesome.

Or perhaps just provide the powerplant as a kit and allow us to build the rest of the light?

This does sound like a neat idea, I hope it gets built. I may still be interested in the current design once more runtime/beamshots/specs are provided.

I would love to do this in a mag charger beacuse this would not require any machining of the body for charging port. If you could send me one i will happily make it a mag charger super duper bad ace light.:twothumbs

 

[Jash]

Question time,

Is the light engine a sole unit that replaces the bulb/reflector in a mag that can be operated from other power sources? Like 4 D size ni-mh batteries.

And if it could, what runtime could one expect from 4 10k mah Accupowers?

If this is a possibility, what would the cost be for just the light engine?

 

[ama230]

Thirty bucks plus shipping. This replaces the reflector and sits in the head and just tighten the head all the way down as tight as it will go. I will post pictures here in a bit. Thanks for your interest...:thumbsup: