Ok.. finally had a bit of time between nano building to 'take a break' yeah right.. and fix the bug in the driver that was driving me MENTAL!
(the bug: the shut down ckt defaulted to 'off'... if it was connected at 'startup' it would say.. 'oh.. there is zero volts on the shutdown pin i must have already shut off' and the hysteresis program held it off no matter what the voltage.. aaarrrgh..
So.. squashed the bug.. glad i was doing the testing at low voltage (1160 bulb).. because as it turns out.. much harder to fix at lower voltages.. when i moved up to the 1166 bulb the problem was much less of a problem.
Oh.. i managed to bump off the voltage setting resistor with the 1160 bulb in there... and it puts Vbat to the bulb in such a case.. i couldn't figure out why it didn't seem to be regulating but the only way to be sure it so turn up the voltage 'til the output voltage stops climbing... well.. the voltage stopped climing at about EIGHT VOLTS... it went right to ZERO! oops! well fortunately i had a different bulb to finish the work... i think i need some more 1160s though i'm clean out.
Oh i just have to know so here i go look.
8.0V on the FIVE volt 1160 stats look like this: (yes i'm completely aware the calculations aren't that accurate when going more than 20%, but it's still interesting!)
4.47A... 35.7W.. 1700 lumen.. 47.4 lumen/watt.. 3761 CCT.. 107% overdrive.. and 66 degrees Kelvin above the melting point.. it did last approximately 1.0 seconds... but i was 'ramping' the voltage.. and in the mid seven volts.. wow did that look pretty!
Now onto the more serious...
First i tested out the circuit with a $4 westinghouse 12V 20W bulb.. and preset the voltage to about 12.5.. so it would be close so i could run the 1166.. the voltage was within 1/10th of a volt when i switched to the 1166..
Setting the voltage input to 14.47 V to simulate running from 4x LiON.. the bulb was getting 12.5V.. at 2.04A.. changing the input voltage from 16.8V to 14.0V (dead cells).. there was no appreciable change in bulb voltage.. 12.50V the whole time..
That works out to:
914 bulb lumens
594 torch lumens.. of course in my case there is not torch.. just the bulb sticking up out of the melting breadboard).
25.7 watts.
2.05 amps
35.6 lumen/watt..
8.2 hr expected life span
3533 CCT
12% overdrive
162K from melting point
86.8% driver efficiency. (just about 4W lost on the circuit)
I plan to run this bulb in a 2D host with a modamag 8AA->2D hacked into series-parallel... that will get me a 1.4AH 14.4V source.. running at 2.04A means about 40 minute runtime.. 900 lumen 2D flashlight.. (600 torch lumen).. it will also not dim in the least 'til the last minute where it'll plummet like a rock down to about 700 lumen before shutting off.
For fun i took a LionHead i had handy and held it over the bulb while i lit it up.. and holy cow what a nice bright light!
here's a picture of the thing operational on the bench:
the rest of the slide show is
HERE
Darn, just noticed i unhooked the second meter which was typically either showing the bulb voltage or the LDO (which btw was 0.006V once the Vin is 12.506V or lower.. however the 15V is the current Voltage IN, not bulb voltage!
Oh some fun trivia on that picture!
Lot's of fun things to see.
the heat-sink for Fivemega's BAM is in the bottom left.. some progold sitting on top of a panel of nano PCBs just above that..
TWO fluke 87s.. a III and a V..
A bunch of nanos almost completed... i love the look of the chargers chips when still attached.. like solders in rows.. the light heads are on the board to the left of the chargers..
Looks like there is a bit of a spool of 10µF caps. .
The heatsink on the FET on the hotdriver got up to at least 182F!.. I was pushing it to the limit to see how much power it dissipated with fresh cells (16.8V!).. answer: 8.77W!
Just above the breadboard is my welders plate held onto a machinist square by a rubberband.. that is normally between me and the bulb for protection both from light and possible explosion of the bulb. It is really wonderful to see the likes of an 1166 running at 12.5V from less than a foot away but through a welder's plate!
In the magnifying lens.. you can see one of my favorite tricks, i hope somebody copies.. you can see the jaws of the vice i use to hold circuit boards while soldering.. and there is a spool of no-clean Kestrel (sp) solder... but see the round circles? those are stacks of magnets.. you can only see the 'top' magnet, but this is the arrangement.. i have 1/4 inch tall stack of 1/8th inch diameter magents.. two of those stacked near each other.. and on top.. a 1/4 inch diameter 1/8th inch thick disc magnet.. arranged like a 'stone henge' arch.. there are two of these and of course they are on the vice 'sideways' so 'top' is actually toward you..
This allows me to pull the solder around in a circle almost effortlessly.. but the magnets 'grab' the solder so it doesn't move much when i'm wetting the tip of the iron
Oh last mention on this picture... the bench power supply.. i honestly have no idea how i survived before getting it.. most useful tool in the shop.
It was less than $200.. it can do up to 60V at 3A or up to 6A at 30V.. has 4 digital displays showing the two independent supplies and their voltage and current..
So.. now that the circuit is completely operational and working exactly as planned.. I suspect in a week or so when i get around to maybe batch 4 of the nanos i'll take another break and finally get the driver assembled into my KIU socket into my 2 1/2D FiveMega.. so i can stop melting my darn 1185 bulbs!
Check back in a week or so.
-awr