Introducing WorldTorch

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Doug Owen

Flashlight Enthusiast
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Jan 30, 2003
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Introducing the WorldTorch Project, a non profit project with the goal to define and develop technologies which will add LED lighting (and other forms of alternative lighting) to people whose current sources of light are less efficient and often dangerous. An example would be the conversion of kerosene lighting (which is expensive and dangerous) to a solar powered / LED system (clean, safe, efficient, inexpensive, renewable). We ask for your feedback and involvement in the design, testing, or any other aspect of the project. We need you to help us bring light to the rest of the world!

http://www.worldtorch.com

WorldTorch Project Background:
A year or more ago, I got started thinking about minimalist lighting systems. Threads along the lines of ‘my sister is going into the Peace Corps, what should she bring?’ got me thinking of maximum efficiency small-scale solar systems. Just enough light to make life better with minimum cost or other burdens.

Research took several directions as you might guess. Of most interest here is work on high efficiency driving LEDs at lower levels, levels typically ignored by most CPFers. This work lead, amongst other places to the ‘discovery’ that small changes in level weren’t significant, I found a factor of 4 (‘two f stops’) a reasonable standard. For example, the PacLite uses twice this (16 times, four f-stops). About this time Scott came along with ‘how do you make a light to drain batteries?’ While the circuit wasn’t ideal for the use he intended (draining 123 cells) due to their already flat voltage curve and ‘unfortunate’ 3.0 Volt nominal voltage I modified my existing design to 3 levels. I then made the prototype, laid out and had boards made, built up and tested the boards for the pilot run. The idea I thought was to use the pilot run to refine the concept and test for and plan production. As pilot runs typically do. I thought we were going to ‘give’ them out, or sell them at cost not profit and get feedback. That got lost somewhere, as these things sometimes do. I don’t know who the ‘customers’ are, nor is it really fair to ask them to help with the project at this point.

There are other volunteers involved who enthusiastically embraced the root idea: Useful light in the third world... Something better than the petroleum based lighting available and something they can afford. One of those individuals is Rob Ludlow, he is responsible for making the web page happen and helping to promote the concept.

We’ve got test units on their way to field tests in India. We’re excited that this idea is starting to take form. We’re trying to tidy stuff up in all areas of this project, I’m sure you know the process. We do have a couple of things ‘up’ on the website (www.worldtorch.com ) and we’d like you good folks to come by and visit and make comments / give us some feedback:

There’s information on the circuit I used for the ‘Milkycandle’.
There is information on how to use the LM317 as a simple regulator.
Perhaps most of interest, a cheap kit ($4) of the parts necessary to make the ‘MC’ regulator (you’ll need to provide the switch). This DIY kit includes on line instructions (nearly done) so you can see what you’re up against (or get the parts elsewhere and make it). In the Gallery section there’s photo of the top and bottom view of the completed board (under half an inch by one, smaller than a 123 cell), also a 12 LED array the circuit later drove quite well on 12 Volts.

It’s our hope; by ‘selling’ the kits (at what we hope is our real costs), is to get the parts and idea out. So folks can come back with improvements and comments so we collectively can make life better for folks we’ll never meet. In the end, the folks that will use this, and benefit from it, will probably not be able to pay for it, no matter how modest we can keep the cost. Someone else, somewhere else, will have to pay that price for them no doubt.

So, that’s the long of it. The short of it is we’d like it very much if you’d come visit the website, maybe buy a kit or two and build them up and try it out. Join our forum so we can share ideas (or even discuss them here?). The important idea is to please contribute your ideas to this project; it’s for ‘a good cause’.

Thanks in advance,
Doug Owen
 
Doug, I have to say World Torch looks a little impractical. It uses a lot of fancy electronics which would have to be imported, and uses 9 volt batteries which are hard to find in a lot of places. At the end of it all you've got an awfully dim light for most kinds of activities.

I think it's best to stick entirely to AA and D batteries, and skip the electronics as much as you can. Just use three or four D cells and use resistors to limit current, if you're using LED's. You're trying to make indoor lights, not anything that has to be tiny and EDC'able.
 
[ QUOTE ]
paulr said:
You know about Light Up The World? http://www.lutw.org

[/ QUOTE ]

Yup, and Engineers without Borders.

LUTW has a track record, for sure, but IMO is short on follow on, and is too 'top down' to be sustainable. The light is installed (no portable options), Luxeon based and uses Lead Acid batteries with no plan for replacement or recycling. It depends on outside labor for installation, leaves no infastructure behind. We see these as issues.

Doug Owen
 
[ QUOTE ]
paulr said:
Doug, I have to say World Torch looks a little impractical. It uses a lot of fancy electronics which would have to be imported, and uses 9 volt batteries which are hard to find in a lot of places. At the end of it all you've got an awfully dim light for most kinds of activities.

I think it's best to stick entirely to AA and D batteries, and skip the electronics as much as you can. Just use three or four D cells and use resistors to limit current, if you're using LED's. You're trying to make indoor lights, not anything that has to be tiny and EDC'able.

[/ QUOTE ]

Thanks for the comments.

Actually, the goal is a minimum of electronics, but still to do a first rate job of using every miliwatt. The LM334 is available in Bombay (India is a trial 'market') for about the same price as here. The problems revolve more around the system and infastructure. It needs a 'local labor content', as well as local ownership if it's going to work (or so we think at present).

It does not use 9 volt batteries, only that battery clip to make stuff easy for CPFers to deal with. The intended source is 3 NiMH cells for the most case, driving LEDs in singles or parallel. Higher levels are centering around the idea of the array of cheaper 5mm parts. If you check the photos you can see one. You'll note the noses have been cut off them to increase the beam spread. Collectively they put out the same sort of light levels as a Luxeon might (both running a bit over one watt), but the beam is smooth, wide and uniform by comparison. And it's cheaper by far (under $3 in LEDs involved). The goal is 'only enought light', in the name of efficiency.

If you followed the Milky Candle thread, folks that try it actually find use for lower levels. On low (still a useful level for a lot of things) the basic light gets over a month continuous run on 3 NiMH AAs between charges.

You're one of the very fellows we're hoping will try the concept and help with the entire system. Which will, of course have to include portable lights to be practical. In fact, if you note the photo on the WorldTorch home page, this is one of the repackaging of the 'Milky Candle' circuit, intended to go into the first inch of a piece of plastic pipe holding the three AA cells.

The base of the system itself will probably be 12 Volts, using a bank of gel batteries we're thinking 3 7aH batteries, two 'on charge' (connected to the solar panel or pedal charger) and one on 'portable desk lamp' duty. Every year you rotate a new battery through, recycling the 3 year old one. Both the main bank and the portable need a Low Voltage Disconnect (which we have on the way to India for testing) to protect the battery. 12 Volts seems to call for 3 LEDs in series.

Doug Owen
 
Hey all!

I've been over to Doug's workshop and have been very impressed with his vision, and his desire to help people... not only newbee CPF'ers, but people accross the world who need an innexpensive and safe form of lighting.

Here's the pic of the "prototype"

wt-01.jpg
 
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By the way, here is a picture of the kit that Doug is providing just at the cost of shipping and parts! As he stated, it doesn't include all of the parts from the circuit he designed for the MilkyCandle (no switch, printed circuit board, etc.) but it has all the important stuff:

wt-kit-buy.jpg


Remember, Doug is providing these at cost because he is looking for people to put help brainstorm ideas and give him feedback so he can help those in the third world.
 
Doug, what kinds of discussions have you had with the people you expect to actually USE these lights, as opposed to those who will be building them? What kind of feedback have they given you?

Also, have you thought about using CCFL's? They should be even more efficient than LED's, and probably cheaper at higher lumen levels that would need big LED arrays.
 
An interesting point.

We get information from this fellow, Michael, who has a very long term commitment (12 years now for he and the wife) in 'the bush' in India with a series of loosely connected villages. He goes 'off line' for half a year at a time when he leaves Bombay. That's where he is now, hopefully our shipments are chasing him down there. Most of his work is berm building (to control floods), small business (sewing, greeting cards, food production for cash, and the like) and social change. He's well educated and connected with others in similar work world wide.

Anyway, his report is we're 'on track' for what's needed. He has a few small systems working (poorly), including a pedal power setup that needs a local built (meaning affordable) charge controller as it is destroying batteries and several small solar systems. Unfortunately, some are six volts as such gear is cheaper in India (a bad voltage to start with with white LEDs). Lighting is typically single 5 mm parts (on the six volt systems) or three in series (12 V) with resistors. His only portable lights are home made on four AA holders with a slide switch and resistor or trim pot in the fourth cell place. It uses local Zinc Carbon AAs. A single LED on the end, the whole lot goes into a plastic bag for waterproofing. It would seem real users there are a frugal with (very dear) electricity as you might think. Not at all like us, use the values we have in thinking about them and you're sure to come to at least some 'wrong' conclusions. I'm sure they no more leave lights on (even very modest ones) than they waste food. Nor are they likely to use more of anything than they need to.

The smallest CCFLs I can find are just too large for typical use. LEDs seem the call for the sorts of levels they're looking for. Given a better condition (with more 'electricity to burn') I suspect folks there would use up to a Watt at a time, from time to time. Consider how much kerosene you'd use if you had to carry it in.

The villages (at least a small part of them) also get power randomly in good weather (when they need it less, of course). The mains can be 'hot' several hours a day, and are available in a few places. This brings up the idea of a storage bank that could be charged up when the mains were on. Turns our India is a producer of big NiFe (nickel iron) cells. Very long lived and non polluting. This may be an option. He's off line (in the bush) now, but will be taking it up when he returns to Bombay. We think it would take renting a generator a few times a year (30 miles when the roads are working), to recharge the bank in wet weather (something they do from time to time already).

He's tied up in social change, making the villages self sufficient, bringing in basic medical services (through training locals), pollution controls and the like. While water there is safe, he's also interested in our UV water purification (for other areas). Lights are only a small part of it. Great resource, to say the least.

He's convinced that the locals have to 'buy in', you can't just give them anything and expect it to last. They raise money and pay *very modest* wages to move huge masses of rock and dirt to make the berms. Thousands of hours a month, at a few cents a day in cash and food from the outside. He's convinced me that to work a lighting system needs to have a local guy responsible. You can't 'plant it and leave'. They need to own it in the truest sense. Make as much as possible, but bear the costs as much as possible as well.

So, yes, I think we're on the right track. We've got some prototypes on their way to him to be sure. We also want to start other trial projects, perhaps closer to home. And more to the point here, want folks like yourself to give it some thoughts and help out if you can?

You asked about LUTW before. I came across Michael in the archives at Engineers without Borders (who also dabble in this area). He'd asked for help with what he saw as a missing key, a charge controller for the pedal power system. It can produce 80 Volts or so OC and folks peddle gel cells into the next life. FWIW, in discussions with him it seems a "Low Voltage Disconnect" (LVD) is perhaps most important. Folks know not to drain the battery down past 10.5 Volts or so, but..... Human nature, but a fact of life. We've got one of a pilot run (six total) on it's way to him (as well as a kit of parts to make a second one to fiddle with). It's a design optimised for low current useage (2.5 mA typical when on), yet controls amps. Low cost (hopefully) with 'Bombay street parts'. The one I have here is doing fine (although it needs some serious field testing). This is getting far afield of the question, and the area of this forum, but as you can see, I kinda like talking about the project.......

Thanks for asking.

Doug Owen
 
Doug,

You've already discussed this a little, but I've gotten some emails from people asking about plans for a luxeon based light... what would your response be?

Also Doug, for anybody reading this thread is there a way to run a Luxeon with the WT kit on the website?

Thanks!
 
Driving Luxeons

I guess my response to Luxeon based lights is 'that's not where I'm at right now'. Nor is it really in keeping with the WorldTorch idea, at least as I see it. Yes, they can be run effectively at the modest levels the WT is trying to address, but I'm sure that's not what CPF folks are looking for. My moneys on the 'bright as the noon day sun end of things'.

That said, yes, the DIY circuit can drive up to 120 mA or so with the supplied parts (you'll need lower current sense resistors that the one in the kit of course). After that you'll need to change to a 'hotter' (higher gain, higher current) transistor. I've used one of the Zetex PNPs for drives up to half an amp or so, plenty for the one watters. You can go to higher currents, but power dissipation is starting to be a big issue. We need to heatsink the pass element as the power gets higher. Even though we're fairly efficient, when you're delivering watts to the load, it's easy for a watt or two to end up in the regulator. This calls for a different approach. I've been thinking of a power FET version to address this, but haven't actually tried it. I may find time to do so.

But, still, I guess my heart's not in the 'more, more, faster, faster' end of this obsession?

Doug Owen
 
Re: Driving Luxeons

I received a couple of kits from WT about a week ago. So far, (I was sick for a few days), I managed to build one board and install it into one of those cheap Taplights. I have a very dark hallway at night. I mounted this at the top of the stairs..hit it when I go up at night, and at the 30ma setting, it casts a very nice "glow" to find your way in the dark. I'm running it on 4 AA NiMh rechargeables...should run for about 2 months this way. I also found these little portable "camping lights". They are a 4 AA source driving a single PR based bulb. I picked these up for $1.99 at an Odd Lots type store. My plan is to convert a few of these to drive 2 5mm leds and run for about a month. This is a great project..easy to build..and mod-able. As a group that promotes lighting up the night, we should all support the World Torch program..besides..it's kinda fun to assemble a little kit..and create long running light!
 
Re: WorldTorch Updates

Okay, long time, no update.

I was talking to Doug about getting a bunch of PCB's burnt for the WorldTorch circuit. From what I understand he's got a design that will drive a luxeon or a 5mm very well at a constant current with very little overhead. The board is the same, but the difference between the two is just swapping a few parts (Doug should comment on this).

Like the circuit that Doug designed in the original "Milky Candle" it will be on a Printed Circuit Board instead of perfboard like the image above. This will give people like me (that are soldering challenged) an easier time building the circuit.

Anyway, before I talk Doug into going in with me on a bunch of these, I'm wondering if there is any interest from the group?

The standard kit with the perf board will still be available for $4.00 shipped. I'm wondering if there would also be interest in a PCB model for a buck or two more?

Again, here is the link to the standard kit:
http://www.worldtorch.com/kit-buy.php
 
Re: WorldTorch Updates

I would be interested in the pcb versions and the parts for the more powerful version. I think this is a great project and should pique the interest of many CPF'rs.

Just a random thought here. I would be willing to pre assmble several of the kits so they could be shipped over pretty much ready to install in whatever capacity needed.
Perhaps Doug could give input as to whether or not this would be helpfull. If so, perhaps interested CPF'rs could volunteer to assemble X number of kits as their "good deed of the day"! :-)
Another random thought would be to make these available to disaster stricken areas in other countries. Many of the areas stricken by the tsunanmi come to mind.

Having too many brain farts tonight, need to get some sleep.

Doug: Feel free to PM or e mail me if any of the above sounds good to you. Being disabled, I don't have much else to do so will help in any way I can.

dimwatt
 
Re: WorldTorch Updates

[ QUOTE ]
moraino said:
I'd like to use it to run 10 26000mcd LED.

[/ QUOTE ]

It should do that handily. Up to say 500 mA total. You can also, of course, drive series strings from higher voltages. So you could drive 9 in three strings of 3 to 30 mA each with 90 mA from a 12 Volt source.

Doug Owen
 
Re: WorldTorch Updates

Dimwatt,

Yer interest is noted, more so your interesting offer.....

This is hitting close to the original idea of World Torch, not necessarily tsunanmi related, but there's a pile of good folks in the thrid world who live in darkness (or perhaps worse, depend on oil lamps....).

Food for thought, thanks. PM sent.

Doug Owen
 
Re: WorldTorch Updates

I second dimwatt's suggestion; I'd also be willing to help assemble these.

The "high-power" version sounds nice too.
For the original version, what would the runtime be on alkies and on zinc-carbon batteries?
 
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