1500W LED Flashlight, >100.000 Lumen, >1Mcd

[Holzleim]

After some Months of development and build time, it is nearly finished now:

• around 1.5 kW maximum power
• >100.000 Lumen total output
• intensity >1Mcd
• 3kg weight
• four groups of light:
  • 1x SBT90.2 behind 62mm TIR optic (tight spot, 560kcd)
  • 4x SBT90.2 behind 30mm TIR optics (medium spot, 500kcd)
  • 8x XHP50.2 in 20mm reflectors (medium width, 160kcd)
  • 8x XHP70.2 without optics (wide flood)
• 3x buck regulator to drive SBT90.2 at 38A and 4x 33A
• 4x boost regulator to drive each 4x XHP50/70 at up to 12A
• 150Wh battery
  • 8x 21700 INR21700-40T
  • 4x 18650 US18650VTC5A
• 12 lighted buttons for direct access
  • Spot tight more/less
  • Spot wide more/less
  • Mid more/less
  • Flood more/less
  • ALL_ON
  • Tactical Flash Mode
  • Momentary spot tight full, all other off
  • Momentary spot tight and spot wide full, all other off
• OLED display for extended info/status
• 2x RGB LED for battery status
• 36W charging circuitry built in, accepting 5V....12V
• USB-C or magnetic tabs for charging
• integrated battery monitoring and balancing circuitry
• vibration motor for important hints like low-bat warning etc.
• multiple temperature sensors (and certainly power foldback upon overheating)
• heatpipes to spread heat from head to body

Will add some beamshots later....

​

View on the front, protective window still missing (will be delivered mid April)

Here the ALL_ON button was pressed, adjusting all channels to ~75% power

Bringup stage of development process:

Heat of DC/DC converters is conducted through PCB to backside of PCB

many, many threaded holes had to be made....combination of aluminium and copper to keep weight manageable

Short video showing ALL_ON in action:
[video]https://app.photobucket.com/images/e277/Holzleim/VID_20210327_223122.mp4?Expires=1617732323&Key-Pair-Id=APKAIUSKKMKJH4ONW7TQ&Signature=CWMj3VzQxlMbU9jB jhfb1XJWlBbjf1Ws6w4-8dx9SZ77Aww-RUrBjTuDH~GXQvJadrMBy1fP-IgVEfHW7ZIEJF0G-DoxyhFLurzRDxFsva8basSPPcvatQa2FVGSfNC9g4NY0Gp3dtZ MLORrWPIVDlNS3lWy5~OLLDhDxVuLqcsj0UwJJd7avViG1dSAo rQ5zYRRYsyAtlUkU16koQkoDzE64XMbP147Z-zPGnb7gno85B1fuVc3rXPpn9pxaYfeXazL5Ub~4v5piF5xYdQ6 rtDrm3YaAqB5KReroX4t~lmNa-WgZF4pwj~4RCfBfbUqKUzpEPiLwRdIsvWRtqwjHw__[/video]

 

[DIWdiver]

Re: 1.5kW handheld LED Power, >100k Lumen, >1Mcd,

All I can say is WOW!

 

[Holzleim]

Re: 1.5kW handheld LED Power, >100k Lumen, >1Mcd,

Ok, lamp is back to full operation....
Took some very quick beam shots:
Our garden, Skilhunt M200, 1200Lumen, 9.000cd:

Mjölnir, tight and wide spot, ~600W, 30.000Lumen, 1Mcd:

Mjölnir, all-full, ~1300W, 100.000Lumen, 1,xMcd:

View behind house across field, tree at 50m, Skilhunt M200:

Mjölnir, tight and wide spot, ~600W, 30.000Lumen, 1Mcd:

Mjölnir, all-full, ~1300W, 100.000Lumen, 1,xMcd:

View behind house across field, small building at 160m (no yet visible here), Skilhunt M200:

Mjölnir, tight spot, ~130W, 6.000Lumen, 560kcd:

Mjölnir, all-full, ~1300W, 100.000Lumen, 1,xMcd:

 

[PhotonWrangler]

Re: 1.5kW handheld LED Power, >100k Lumen, >1Mcd,

Damn. That's probably visible from space.

 

[datiLED]

Re: 1.5kW handheld LED Power, >100k Lumen, >1Mcd,

All I can say is WOW!

Agreed. That thing is insane!

 

[jeffosborne]

Re: 1.5kW handheld LED Power, >100k Lumen, >1Mcd,

Good job! I do wonder about ventilation and heat.
I see a fan in one of your photos, but I see not vent holes in the unit.
Is there a fan to help cool this beast, or is it all passive?

By the way, bare aluminum dissipates very little heat via infra-red.
If you paint the bare aluminum, it will run much cooler.
It is counter-intuitive, but real.

Best regards!
Jeff

 

[badtziscool]

Re: 1.5kW handheld LED Power, >100k Lumen, >1Mcd,

I don't know how I missed this post. I love seeing these types of builds! What was the reasoning for using two different battery types? Do they power the different sets of LEDs separately?

Thanks for sharing.

 

[Holzleim]

Re: 1.5kW handheld LED Power, >100k Lumen, >1Mcd,

@jeffosborne: The lamp has no active cooling, just passive using a lot of metal and the heatpipes to spread the heat over the hole surface. From my experience until now this if fully ok so far, can use it outside with an average power of 100 - 200 W, depending on weather (temp, wind). In this mode of operation I think heat dissipation by convection is far more than by radiation, because it is not very hot (30-40°C). For short term high power the total weight of 3kg has a large heat capacity, so that works good to use the momentary-full-power buttons to spot in the distance with ~600W spot-light, while walking/running around with ~100W flood light.
@badtziscool: The battery is a 3p4s setup, I had to use 8x 21700 and 4x 18650 to make it mechanically fit. Going to 12x 21700 would not had left enough space for the height of the power-inductors on the PCB in the power section.

 

[TheFraz]

Re: 1.5kW handheld LED Power, >100k Lumen, >1Mcd,

Wow! Very impressive for sure.