Help me design a 25K lumens searchlight

HugeOne

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Feb 5, 2010
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I want to make compact ultra powefull light.
My idea is 12 SST-90 in a 3x4 config measuring 40mm x 33mm (All leds touch each others)

The array will be liquid cooled, by soldering the led to 5mm square copper pipes.

My problem still, is to find 10mm optics that will give me 30 degrees FWHM or less for those 12 leds

Any idea?
 
I would leave a little space between the emitters: 1. because even with liquid cooling the heat will be very intense and 2. because as deadrx7conv said you need some space for optics/reflectors.

PhotonFanatic sells optics and holders for SST-90 in his thread over at the MP.

rayman
 
With the die size of the SST LED's, you're not going to find small optics that give you anywhere near that beam width...

What do you mean by "liquid cooled?" You say something about liquid filled copper tubing, and, while that's good for moving heat to another area, but if you don't significantly increase surface area to dissipate that heat in another area, then your liquid filled copper tubing is not a heat-sink, in the sense that it will help dissipate heat elsewhere, but instead a thermal mass, which will heat up quickly when the light is lit up.
 
I want to make compact ultra powefull light.
My idea is 12 SST-90 in a 3x4 config measuring 40mm x 33mm (All leds touch each others)

The array will be liquid cooled, by soldering the led to 5mm square copper pipes.

My problem still, is to find 10mm optics that will give me 30 degrees FWHM or less for those 12 leds

Any idea?
12 sst 90 in a space smaller than maglite head??????? lol.
soldering leds to a heatpipe????
your problem is a lot more than just optics.
good luck.
 
12 sst 90 in a space smaller than maglite head??????? lol.
soldering leds to a heatpipe????
your problem is a lot more than just optics.
good luck.

Sorry for not giving more infos,

Soldering to a heatpipe must be quite a challenge :)
I mean to solder the led along a square copper pipe in which fresh 60-70degree water will constantly circulate.

Indeed such a small optic for such a large die is probably beyound the laws of physic.

Using the ledil "lily" reflector should make the light 68mm by 91mm, bit large for my use, but possible.
 
Sorry for not giving more infos,

Soldering to a heatpipe must be quite a challenge :)
I mean to solder the led along a square copper pipe in which fresh 60-70degree water will constantly circulate.

Indeed such a small optic for such a large die is probably beyound the laws of physic.

Using the ledil "lily" reflector should make the light 68mm by 91mm, bit large for my use, but possible.
it is not optics,
sst90 mags can't run full power for long, even massive heatsink for 1 led isn't enough, there was a thread here iirc someone turned halogen spotlight into sst 90 spotlight, heatsink was a lot bigger than for maglite, it also had a fan, yet still it was not capable of sustaining heatransfer at full power.
and you want to fit 12 sst90 (110amps at full power) into a base the size of even 68 by 91????? lol you'll melt your optics and leds along with it.
my advice search all sst90 mods on this forum, you will have lots of answers to questions you have not thought of yet.

heat pipes aren't cooling devices, they transfer heat, once i took apart a small comp that had a cpu on a aluminium base not bigger than cpu itself, 1 heatpipe about 3\16 and 6 in long was screwed into a heatsink 4 times the size, and with all fins pbly 100 surface area, that was for only 1 cpu. the reason for pipe was small size and arrangement, it is always better to have as short heat path as possible, heatpipes do exact opposite, they are necessary evil


also afaik spotlights are made for throw, i assume you want it as well , but tiny reflectors will not give you much throw, you'll have wall of light (before you melt everything) but not much throw, diametre and depth of reflector produce throw. that is why all spotlights have big reflector.
i have 3xp7 mag it is a wall of light, but xp-g with 2x as big reflector throws a lot farther.

if you want tiny size spotlight, get a white laser, and defuse the beam
 
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Is there any way you can use XP-Gs instead? I would think that would be a heck of a lot more efficient and thus produce much less heat. Yeah I realize that is a crapload of emitters, but 12 SST-90s seems about as crazy. :)
 
heat pipes aren't cooling devices, they transfer heat, once i took apart a small comp that had a cpu on a aluminium base not bigger than cpu itself, 1 heatpipe about 3\16 and 6 in long was screwed into a heatsink 4 times the size, and with all fins pbly 100 surface area, that was for only 1 cpu. the reason for pipe was small size and arrangement, it is always better to have as short heat path as possible, heatpipes do exact opposite, they are necessary evil

I don't want to use a heat pipe, heat pipe rely on a heat sink, which have a finite heatsinking capability.

I'm talking about water cooling, leds gonna be soldered on the side of a four faced copper tube. In that tube a endless supply of cool water is then feed.

Heating 1 L\min by 10F take about 390W of power.
 
I don't want to use a heat pipe, heat pipe rely on a heat sink, which have a finite heatsinking capability.

I'm talking about water cooling, leds gonna be soldered on the side of a four faced copper tube. In that tube a endless supply of cool water is then feed.

Heating 1 L\min by 10F take about 390W of power.

you mean radiator, fan, and water pump liquid cooling???
sounds like you building overcomplicated light, it would be a lot easier to go with hid, for now 25k lm reliably is hid territory, but hey, i guess you like challenges, good luck, keep us posted.
 
Water, pump, radiator/fan..... and you're worried about the size of the light?

What about the generator you'll have to lug around to power it?

Are you trying to retrofit an existing housing?

And, what will this searchlight be used with? heli? boat? ATV?
 
This is in the transportation forum so my guess is that he has a hole to mount it in with lots of space behind it to do all the cooling. I think you guys are overthinking it.

Good luck with this and keep us updated.
 
Have you thought about using several computer CPU heatsinks? They can dissipate alot of heat.

c08.jpg
 
www.micropumps.co.uk

Found the pump for the cooling, 650ml/min only 12g
Believe it or not, this is going on a rc helicopter.

8Ah li-po pack should yield 12min rum time.
 
What about something to radiate that heat... Sure, the pump will work, it'll definitely circulate the water, but even still, once that water is fully heated it is pointless to pump anymore... And with 12 SST's that won't take long at all.

Do you have a radiator that is capable of dissipating anywhere near that amount of heat? I realize this will have lots of air flow, but still.

Also, most Li-ion chemistries, even IMR, will not safely handle enough current draw for this to be anywhere near 25k lumens. You're going to need to take a look at Lithium polymer for that, or your flying searchlight will be more of a flying explosive event.

How big is this heli, anyway? You're talking a great deal of weight and size, not to mention the power requirements.
 
Yes, 8Ah li-polymer (120A capable)

The heli is a 90size (4ft 10" rotor diameter) can lift 5lb without a sweat.

The rad I'm looking right now is a 150mm 120mm unit made for PC water cooling. Placed over the boom directly under the prop wash.
 
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