Made my first LED lamp.

[Optical Blender]

I was using a small/cheap halogen lamp, but eventually the heat got to it. I decided to try to build an LED replacement. It probably cost more to build than i could have bought one for, but what's the fun in that?

The heatsink and neck mount are both 6061 aluminum. I'm using the AC powered LED from superbrightleds, so there is no transformer. I reused the old lamp's power cable/switch and bendable neck. I'd like to build a neat multi-joint arm to dress it up, but that's pretty low on my priorities.

I'll admit i don't know much about AC safety, so could you guys help me out before i start to use the thing? Do i need to switch to a three prong plug so i can ground the heatsink? I know i'll need an in-line fuse. I will order one once I compile a shopping list. I should also re solder the rightmost wire in a way it doesn't travel over/near the surface mount resistor. Maybe add some epoxy in the base of the neck, to prevent the wires from pulling through.

 

[Hondajt]

that is really cool! What are you going to be using the lamp for?

Are you a machinist? That heatsink seems really neat. Looks like it is rather overkill though, but I am new and just learning, so I could easily be wrong.

 

[purduephotog]

1) Fuse. Fuse the wires going in.
2) Ground. Ground that heat sink with a third wire.
3) Ground. Ground the connector chassis with another wire, tie to heat sink.
4) Use a grounded plug.
5) Isolation transformer. You're not pulling that much current so a small one would work.

 

[Illum]

that is really cool! What are you going to be using the lamp for?

Are you a machinist? That heatsink seems really neat. Looks like it is rather overkill though, but I am new and just learning, so I could easily be wrong.

nope, undersize might be the concern. Ariches burns pretty hot, but its the few LED varieties designed to be directly driven with line voltage:)

the fin design looks awesome though, care to share why the design asked for sharp peaks but with filleted undersides? ;)

 

[Optical Blender]

that is really cool! What are you going to be using the lamp for?

Are you a machinist? That heatsink seems really neat. Looks like it is rather overkill though, but I am new and just learning, so I could easily be wrong.

I need a simple/bright light to use while setting up milling operations. My old cheap one broke.

I dabble machining to keep my other hobbies affordable. I am a novice for sure. I recently converted my small mill to CNC, so i was looking for something to make with my new abilities.

1) Fuse. Fuse the wires going in.
2) Ground. Ground that heat sink with a third wire.
3) Ground. Ground the connector chassis with another wire, tie to heat sink.
4) Use a grounded plug.
5) Isolation transformer. You're not pulling that much current so a small one would work.

Thanks. I'm glad i asked before i started to use the thing. I'll have to read up on isolation transformers as i've never heard of them before. Initial research shows they are a shock prevention device. Sounds like a good thing to have.

nope, undersize might be the concern. Ariches burns pretty hot, but its the few LED varieties designed to be directly driven with line voltage:)

the fin design looks awesome though, care to share why the design asked for sharp peaks but with filleted undersides? ;)

At the time I didn't feel like calculating the performance of the heatsink, but i'll agree the fins are too short and thick to be that great at removing heat. It will see short duty cycles, so i'm not too concerned.

The design really was an impulse. I was thinking about cutting the fins to write a name or logo, but the software i use didn't want to play nice. Instead it ended up looking like some kind of shoe tread. I just made what i thought looked cool with the tooling i had. My small tooling is too short to cut deep fins and i'd rather not buy a silting saw because the project is already not cost effective.

The inner corners of the fins are filleted and the outers are sharp because i forgot to round the outside corners in the CAD software. The inners are from the radius of the tooling. I didn't notice it until i already removed it from the machine, so i didn't feel like correcting it. Like i said i'm a novice.

 

[Illum]

Like i said i'm a novice.

And a darn good one with cool designs too:thumbsup:

Milling halogens will probably burn hotter, with the LED recessed in this way occiasional drops of drilling fluid on top shouldn't hurt either :)

 

[deadrx7conv]

Thats a 2-watt Acriche, right?

Heat sink size looks reasonable.

 

[purduephotog]

I forgot to mention: Pot the LED. Put some blue RTV silicone (gasket stuff for sensors) around the inside- cover all exposed solder beads and electronics. You might want to make up a little plastic jig and put some vaseline on it so you can remove it later around the LED itself. That way you won't get a shock.

 

[Ken_McE]

I decided to try to build an LED replacement. It probably cost more to build than i could have bought one for, but what's the fun in that?

Agreed.

I'll admit i don't know much about AC safety, so could you guys help me out before i start to use the thing? Do i need to switch to a three prong plug so i can ground the heatsink?

It will run without it, but three-prong is the way to go.

Maybe add some epoxy in the base of the neck, to prevent the wires from pulling through.

The traditional way to address this is to add a knot to the cord so it can't pull down and strain your connections. This makes it easy to take apart sometime in the future. You might also want to put a cover over the LED - either a screen or a piece of glass/plexiglass. This way you can reach out and grab it to adjust it without having to look at it. Two watts won't really burn you, but it could distract you while you're trying to concentrate on something.

:welcome:

 

[Optical Blender]

Thats a 2-watt Acriche, right?

Heat sink size looks reasonable.

yeah, it's 2 Watts.

Thanks again Illum, purduephotog and Ken_McE. I'll make the required changes.

lovecpf

 

[deadrx7conv]

Mill a channel for the wiring so that you can put a clear plastic cover on it.