Headlamp with 18650 battery In the previous article we looked at a very good modern chip - a lithium battery charge controller, now it's time to apply this circuit
Headlamp with 18650 battery

Headlamp with 18650 battery

In the previous article, we looked at a very good modern chip - a lithium battery charge controller, now it's time to put this circuit into action by upgrading several flashlights. Next, see a couple of applications of memory boards with TP4056 in flashlights:

Batteries are taken from old cell phones, found with the same capacity, balanced and soldered into a block. In the first version, 1.5 A, in the second, 1 A. They charge quickly - about 1-3 hours, depending on the current PSU used.

Then I started reworking another old camping flashlight for a 18650 lithium battery, painted a signet under it, came out almost like the original, but smaller. I tried charging, it works. I'll take the whole lantern.

But I completed another old camping flashlight. It is possible to change lenses for different focusing of the light flux. I replaced the acid battery with a 18650 type battery and added a charger on the same TP4056, the capacity of the used battery is 1.3 A:

One more case. They gave me a good case from an ancient flashlight on an incandescent bulb, with recharging from the mains.

The gel battery built into it was long and hopelessly dead. After a little thought, it was decided to build in it a block of parallel lithium batteries 4 pieces of 800 mA each, and expand the functionality by embedding two LEDs at 60 mA and 150 mA into the case.

In place of the removed retractable fork, an additional aluminum plate-radiator was cut out and an smd LED was screwed on for a working current of 150 mA. And in place of the former light bulb, an 8 mm round 60 mA LED was installed.

There was a lot of free space inside, respectively, a ready-made memory was built into the flashlight for, again, TR4056. The LEDs on the charger board fit perfectly under the hole of the former power LED. Under these charge indication LEDs, a Plexiglas cone indicator was machined and glued into the case. The result was a compact and resource-intensive (3.2 A) flashlight with a recharge from 5 V.

A protective plexiglass was added to the case to protect the LED from dust. And this is a disassembled case, for a more understandable visual acquaintance with the filling of the converted flashlight. There is still an empty space left, it is quite possible to add a step-up converter for recharging a cell phone.

Thus, old electronic structures and devices can be given the opportunity to serve further, using a modern electronic base in a new technical quality. And all this will help to do a small cheap chip 4056. With you was Igoran.

Headlamp with 18650 battery

On inferior 5 mm LEDs for a 18650 lithium battery. Here the scarf was removed, and instead a home-made one was made on new original (the crystal is quite large) 2835 1 W 350 mA LEDs (for monitor backlighting), they have a positive substrate. But you can also use the usual 2835 by changing the polarity to the standard one. On Ali, they cost 3 cents.

When installing a new board, you need to grind off the mounting column flush with the reflector cups, the more we grind, the better the focus in the center without dimming is obtained. The charger is used for 5 V 500 mA in narrow cases, it is installed at the top under the battery (down with details), the board with the leads is covered with a thick film - the substrate from the ATX power supply unit and the battery is glued on top of the molecule.

As a driver, an AMC7135 chip is installed at 3.2 V 350 mA, 5 LEDs have 70 mA each, which prevents them from heating up with good light output. It turned out quite solid and durable flashlight, which will now last a very long time.

Flashlight conversion to Li-Ion 18650

Another more modern flashlight with mains charging, the insides are replaced with 18650 batteries and 5V USB charging.

LEDs of 7 pieces were replaced with higher quality 5 mm "hat" type and with a brighter glow. But since the flashlight had two modes, I decided for the future to remake the board for two types of LEDs, 6 pieces of 5 mm in a circle and a central powerful CREE LED or 1 W, it fits on the substrate just right. In this form, diffused light and beam light are obtained.

The driver is standard on the LM358, the current of the central LED is selected within 120 mA, which is quite enough for lighting and practically does not heat the substrate. The heating of the LED substrate will start from 150 mA, but if you use a double-sided fiberglass, you can use the other side as a small radiator, although this is still superfluous, since the luminous flux will only be slightly brighter, but the LED substrate will heat up quite strongly.

Collected, checked, everything clearly came up under the reflector, it shines quite brightly. The light came out cold white from 5mm LEDs and slightly warm white from CREE.

Alteration flashlight A420

Alteration of the lamp "A420" from LDS to LEDs. A friend asked me to look at the flashlight, whether it is possible to make anything sensible out of it, since with an LDS lamp it quickly eats up batteries, and it is a pity to throw it away.

I looked, I thought, the power comes from 4x 1.5 V batteries, you can make a flashlight for 1 - 4 26650 batteries, but this only partially solves the problem, it would be more sense on the LEDs from the flashlight. It was decided to leave the batteries, but convert the flashlight to LED.

Chinese penny LEDs 2835 for 3-3.6 V 60 mA were taken as a light basis, the total current was calculated at 640 mA so as not to overheat the crystal. There is enough light with them, but if you need it brighter, you can put brighter LEDs, and replace the R2 resistor on the driver with a variable one, there will be an additional brightness adjustment.

The printed circuit board was copied and remade for the driver you liked on the LM358, the LED matrix racks for the contacts of the scarves were taken from the old monitor board, they fit perfectly. A little later, the board was supplemented with a TR4056 charger, the power connector can be installed on the cover, now you can also put any suitable batteries in the flashlight by screwing the terminals directly to the racks.

Alteration of the T-50A flashlight

The canopy of the T-50A model was also redesigned.

After a test for the duration of the flashlight from the built-in battery 26650 5A, after a while the LEDs blinked. I thought it was overheating, but separately from the driver, they shone wonderfully and did not get very hot. The Chinese op-amp LM358, once bought by the party, turned out to be problematic; when replaced with the original, the problem with blinking disappeared.

Discuss the article RECONSTRUCTION OF THE FLASHLIGHT UNDER 18650 BATTERY

Literally "on the knee" the lantern was disassembled, the network connector was removed (the charge was from 220 in the original) and "interfering wires" - they could not be touched in fact :)
Instead of a native battery, a power bank with a can of 2600 was attached, the native cover was removed from the power bank (metal is useless near the printed circuit board), fixed with electrical tape so that the structure does not crumble during vibrations or possible falls of the background.


In fact, everything can be done MUCH more accurately, but I was interested in the simplicity and speed of the solution at the time of the rework.




Something like this happened (the wires could not be pulled out through the power bank, but at first there was an idea for a slightly different location, I didn’t redo it).
The power bank itself was fixed by inserting it into the former network connector, even without additional. fasteners quite firmly "sits"




Main advantages:
The lantern is alive!
Pretty easy and inexpensive!
It is easy to change the battery (in case of failure) - they are common and inexpensive.
You can charge from any USB (including in the car), as well as, if necessary, use the flashlight itself as a power bank. There is a lamp charge control.

The flashlight shines normally. I didn’t try to detect in time - but it shines for a VERY long time, for several hours for sure, I didn’t try to discharge it at once.

The new flashlight… lay down for a year and the battery died (as it turned out, this happens with all such flashlights, 4 friends have the same thing) - it’s a pity to throw it away (I used it once), it’s very difficult to find a new battery + battery cost = flashlight cost ... found a simple solution…
Interestingly, the lanterns had different operating conditions (by February 23 they were donated to employees) - but they all died “at one o'clock”. Naturally it's a shame, just needed, "new" and on you :)))


Having tried to search for similar batteries in special stores and markets, I came to the conclusion that it is completely inappropriate to buy such a battery for the cost of a flashlight. I did not find a cheap alternative, besides, the characteristics of the battery were embarrassing ... Ie. 5v strained when converting to a different type of battery ...


And there was no desire to radically alter the charging and the flashlight.
At first there was an idea to plug in 18650 - but the voltage per volt is lower (how the lantern will burn - again alterations ... + disassemble / assemble for charge ... in short, problems again :(

The solution was found to be very simple - buy an external cheap power bank, which already gives out 5v at the output, has a built-in charge system CHEAP AND TASTY :)

In fact, the native battery had 2Ah. It is clear that in our case there are all kinds of unnecessary losses - but the price justifies the means + some advantages appear :)

Literally on my knees, the lantern was disassembled, the mains connector was removed (the charge was from 220 in the original) and, well, “interfering wires” - you could not actually touch it :)
Instead of a native battery, a power bank with a can of 2600 was attached, the native cover was removed from the power bank, secured with electrical tape so that the structure would not crumble during vibrations or shocks.
In fact, everything can be done MUCH more accurately naturally, but I was interested in the simplicity and speed of the solution.





Something like this happened (the wires could not be pulled out through the bank, at first there was an idea for a slightly different location).
Those. The power bank itself was fixed by inserting it into the former network connector, even without additional. fasteners quite firmly "sits"

Main advantages:
The lantern is alive!
Pretty easy and inexpensive!
It is easy to change the battery (in case of failure) - they are common and inexpensive.
You can charge from any USB (including in a car), and also, if necessary, use it as a power bank (depending on the quality of the latter).

The flashlight shines normally. I didn’t try to time it - but it shines for a VERY long time, several hours, probably, I didn’t try to discharge it at once.

I plan to buy +23 Add to favorites Liked the review +38 +71

Choosing and acquiring a flashlight is a difficult and tedious task. At least for me. I approach this matter with all meticulousness and responsibility. It is necessary to take into account all the advantages and disadvantages of the product. Type and capacity of batteries, parameters, weight, degree of water resistance and much more. So that he does not fail at the most inopportune moment. I wanted to buy a small pocket flashlight, waterproof, powered by a single 18650 battery. However, I could not find the desired product in local stores. I was already thinking about ordering in an online store and, after waiting 2-4 weeks, to get what I needed ... But suddenly I stumbled upon a thing that almost suited me. Almost. The flashlight had the dimensions I needed, and all the necessary qualities, but there was one “but” - it worked on three AAA batteries (little fingers).

Having a special container with four constantly charged 18650 batteries in my backpack, I categorically do not want to use other batteries. Especially as small and not capacious as little fingers. But there is always a way! After examining this flashlight in the store, the modification scheme matured right there, and without thinking twice, I bought it in order to remake it in my own way in the near future free time.

It will take

• Boron machine with a cutting disc (or emery machine).
• Soldering iron, tin and flux.
• Plastic tube (for body insert).
• Aluminum self-adhesive foil.
• Scissors.
• Stationery knife.
• File.
• Sandpaper (or sandpaper).
• Second glue.

Flashlight makeover

The main problem is that the "native" power supply of the flashlight (the case in which three AAA batteries are located) is slightly wider, and one and a half centimeters below the 18650 battery.

This means that the body of the flashlight itself will be small in height for 18650. In terms of voltage, 18650 is almost identical to three little finger batteries, 18650 produces 3.7 volts, and three little finger batteries in total give 3.6 volts (1.2 × 3 \u003d 3.6) . So, if the body is small, it is necessary to lengthen it. It was quite problematic to find a suitable insert tube that would fill the extra space between the battery and the walls of the flashlight. I, in the end, could not get a suitable insert ... I just took a more or less suitable tube, which includes 18650 and, installing it on a drill, removed the extra thickness from the rotating workpiece with coarse sandpaper! So, let's disassemble the flashlight. We unscrew the front and back parts of the flashlight from the middle one, and set it aside. Using a drill with a cutting disc, we saw the middle part of the flashlight body into two equal halves.

We grind the cut edges with sandpaper so that they become even and smooth.

Next, we insert the insert tube into the front of the flashlight with a reflector screwed onto it, put on the back part from above with the bottom screwed onto it with a button. The result is a new, elongated body that fits the width of 18650.

Now we adjust the height, insert the battery into the case, measure the excess from above, take out the insert and cut off the measured edge with a clerical knife.

Even in the design of the flashlight, inside the case, there are two metal rings and a metal strip that connect the plus and minus on the switch button. Naturally, after lengthening the case, the metal strip became a bit short for the new design. I also had to fit the rings under the liner tube.

A layer of soft plastic was quite easily and quickly removed with a file from the edges of the liner, where the ring should sit.

The second, front ring, was inserted inside the front of the flashlight, where the reflector, lens and LED are located, so I didn’t have to mess around with it. With a metal strip connecting the rings, let's do it easier; simply stick a strip of self-adhesive aluminum foil on the liner.

We put the back ring on the prepared back of the liner.

Now let's deal with the "head" of the flashlight. On the former power supply, with little finger batteries, there was a small bulge on the positive contact, which was in contact with the plus. On the 18650 battery, both contacts are flat, therefore, I had to solder the same spring to the positive contact of the front of the flashlight that is on the negative, rear part.

Now we put the new building together.

All the details fell into place like family! It remains to drip with super glue the joints between the liner and the sawn edges of the case in order to restore the tightness. There is still space left, more precisely, it turned out to be a groove that was formed after the sawn ends of the old case were installed on the liner. Here the matter of each individual; before gluing all the parts, it is possible to fit a piece of tube of suitable parameters to this place. I decided to just wrap a little scotch tape and black duct tape in there; may be needed somewhere.

Thus, we "transferred" this device from three batteries to one, equal to them in voltage, thereby saving ourselves from the tedious charging of the power supply with small and not capacious batteries.

The above changes did not affect the qualities of the flashlight (brightness and water resistance). Unless, he became one and a half centimeters longer.