DIY Maglite USB Rechargeable 18650 and LED Upgrade

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简介:DIY Maglite USB充电18650和LED升级

About: Just another tinkerer

大家好,

几年前我有幸得到很多of Maglite 3 D-cell flashlights from my local metal recycler, these are the models before LED's became the norm and while I absolutely love using them having to replace the batteries so often led to them gathering dust in my closet.

快进几年......我在所有项目中开始使用可充电的锂离子,当我需要一个新的手电筒而不是花钱在一个新的手电筒上,我决定开始改装我的所有Maglite的李离子电池配有USB充电和明亮的新DIY LED灯泡。

让我们开始吧!...

补给品

第1步:你需要什么:

要转换刷灯,您需要以下内容:

- Maglite or similar flashlight

该转换将在任何2-7个D-Cell Maglite上工作,如果持有者直径降低,也可以使用C-Cell Maglite。

- 18650 Li-ion batteries

The amount of batteries required is up to you, personally a single battery gives me more than enough work time and reduces the recharge time.

我仅推荐使用三星,索尼,松下等的可信赖的电池品牌。

亚马逊 - 18650年

- Li-ion charging + protection board

Amazon - TP4056

- 3.3OHM 1W电阻

Amazon - Resistor Kit

- 一个旧的金色灯泡

- 1W LED

亚马逊 - 10PCS 1W LED

- 拯救的8mm直径电容器

- Access to a 3D Printer

- 烙铁+焊料

- Kapton胶带或电气胶带

- 5/64" / 1.98 mm Hex key

- 约米〜24AWG电线

It's a good idea to have one half of the wire red and the other half black to not accidentally confuse the polarity.

第2步:电池支架:

为了将电池和充电模块保持在手电筒的主体中,我决​​定打印与D细胞电池直径相同的保持器,以便它可以滑入旧电池的地方,而无需改变身体的任何东西手电筒。

我设计了Tinkercad的支架,并为单个电池或双电池提供。

对于C-Cell Maglite,您需要减小支架的直径,以便它适合手电筒。

在充电过程中,TP4056充电模块确实升温了很多,因此我建议在PETG或ABS中打印支架。您还可以减少通过更改模块上的电流设置电阻而产生的热量,但这会增加充电时间。TP4056 INFO

我在ABS中打印矿,并没有标准的1AMP充电电流没有问题。

Step 3: Assembling the Battery Holder:

现在你有印刷持有人,我们可以开始组装它。

首先,我们需要为我们的电池添加通向,这样做,您需要预热焊锡,以确保它很好。

在18650年的电池上,正极端子是略微抬起的侧面,侧面略微抬起,它在顶部有一个轻微的脊,负是普通的平坦部分。如果您不确定,您可以谷歌电池上的型号进行确认。

- 使用单个电池时,只需将大约15cm的电线焊接到正(红色/黄线)和负(黑线)侧。

只能剥线的一侧,你将焊接到电池以避免缩短另一端,要特别小心我喜欢在电线的另一端使用一些电气胶带。

- When using two batteries we want to connect them in parallel, I stripped the positive wire about 3cm and pre-tinned it, placed the two batteries side by side positive facing up and then soldered the wire across the two positive terminals. I then "folded" the two batteries together so that the positive terminals are pressed together with the positive wire coming out between them.

对于负面的负面,我只是将一个负面焊接到另一个负面的电线,然后焊接在将去充电板上的负面上。

现在,您可以使用一些Kapton或电气磁带固定电线。

如图所示,通过保持器送到支架,然后将电池按到支架中,它应该单击到位。

根据照片,我们现在需要在我们的充电模块上焊接:

- Positive from the battery gets soldered to B+ on the board

- 来自电池的负面焊接到电路板上

- a ~20cm red wire gets soldered to OUT+ on the board

- 一个〜20cm的黑色电线焊接到董事会上

- 从板上通过支架馈送电线,使其在另一侧出口,然后将电路板压入支架,支架有一个柱子,将停止电路板的推动太远。

锂电池安全:

“危害
锂电池通常是安全的,不太可能失败,但只有只要没有缺陷并且电池没有损坏。当锂电池无法安全运行或损坏时,它们可能会出现火灾和/或爆炸危险。不当使用,储存或充电损坏也可能导致锂电池失败。根据适当的测试标准(例如,UL 2054)测试电池,充电器和相关设备。NRTL认证(适用)和产品召回,有助于识别设计,制造和材料质量的缺陷。锂电池的损坏可以立即发生或在一段时间内发生,从物理影响,暴露于某些温度和/或不当充电。可能会损坏锂电池的物理影响包括掉落,破碎和穿刺。当温度过高时,可能会发生对所有类型的锂电池的损坏(例如,高于130°F)。外部热源(例如,打开的火焰,加热器等)也可以在具有缺陷或其他原因的缺陷或损坏的细胞中加速失效。当电池本身或电池周围的环境在充电期间,当电池周围的环境或环境周围的环境下面时,可能会发生锂离子电池的损坏。 Charging in temperatures below freezing can lead to permanent metallic lithium buildup (i.e., plating) on the anode, increasing the risk for failure. Charging a device or battery without following manufacturer’s instructions may cause damage to rechargeable lithium-ion batteries. For example, some manufacturer-authorized chargers will cycle the power to the battery on and off before it is fully charged to avoid overcharging. Since ultra-fast chargers may not cycle power, do not use them unless the manufacturer’s instructions include them as an option. Heat released during cell failure can damage nearby cells, releasing more heat in a chain reaction known as a thermal runaway. The high energy density in lithium batteries makes them more susceptible to these reactions. Depending on the battery chemistry, size, design, component types, and amount of energy stored in the lithium cell, lithium cell failures can result in chemical and/or combustion reactions, which can also result in heat releases and/or over-pressurization. In chemical reactions, by-products from the electrolyte solution and electrodes can increase the pressure in the cell to the point where the cell walls expand and by-products leak out. Chemical by-products usually include carbon monoxide, carbon dioxide, hydrogen, and hydrocarbons. In many cases, the by-products are also combustible and could ignite. In combustion reactions, a thermal runaway releases byproducts that may ignite to cause smoke, heat, fire, and/or explosion. The by-products from a lithium battery combustion reaction are usually carbon dioxide and water vapor. In some lithium batteries, combustion can separate fluorine from lithium salts in the battery. If mixed with water vapors, fluorine may produce hydrofluoric acid, which is particularly hazardous because workers may not feel its effects until hours after skin exposure. Prevention Workplace injuries from lithium battery defects or damage are preventable and the following guidelines will assist in incorporating lithium battery safety into an employer’s Safety and Health Program: Ensure lithium batteries, chargers, and associated equipment are tested in accordance with an appropriate test standard (e.g., UL 2054) and, where applicable, and certified by a Nationally Recognized Testing Laboratory (NRTL), and are rated for their intended uses. Follow manufacturer’s instructions for storage, use, charging, and maintenance. When replacing batteries and chargers for an electronic device, ensure they are specifically designed and approved for use with the device and they are purchased from the device’s manufacturer or a manufacturer authorized reseller. Remove lithium-powered devices and batteries from the charger once they are fully charged. Store lithium batteries and devices in dry, cool locations. Avoid damaging lithium batteries and devices. Inspect them for signs of damage, such as bulging/cracking, hissing, leaking, rising temperature, and smoking before use, especially if they are wearable. Immediately remove a device or battery from service and place it in an area away from flammable materials if any of these signs are present. If batteries are damaged, remove them from service, place in fire resistant container (e.g., metal drum) with sand or other extinguishing agent and dispose in accordance with local, state, and federal regulations. Contact a local battery recycling center for disposal instructions. Follow manufacturer’s guidance on how to extinguish small battery fires, which could include using ABC dry chemical extinguishers, Class D fire extinguishers (for lithium-metal), dirt, or sand."

第4步:修改开/关开关:

现在我们需要拆卸手电筒。

- Screw off the front reflector housing and the back battery cap.

- 撬出橡胶开关盖,它应该相对容易地拉出。

- 现在,您需要将十六进制键滑入开关的中心孔并在后面松开Grub螺钉,如果这是您第一次拆卸Maglite,则有几个有用的视频。

- 如果您的手电筒没有任何电池泄漏或腐蚀,开关应只是在桌子上轻轻拍摄后面。如果不是,你可以轻轻地从前面锤出来。

一旦拆卸,我们需要修改开关一点,因为它将不再抵靠电池的电气连接。

- 在开关中间的底部,将有一个弹簧与旧电池的正面接触,到这个弹簧我们将在电阻上焊接,然后从充电模块的另一端焊接正线电阻。如果您有热缩管,您可以用它盖住,或者只需用电动胶带卷起您的连接。

- 然后我们需要将负电线从充电模块焊接到附接到螺母的金属板,其中开关GRUB螺钉通过,为了使电线配合,我将凹槽熔化到金属板下方的开关壳体中。烙铁。

Step 5: Disassemble the Old Bulb:

现在是时候开始制作LED灯泡了。

首先,我们需要拆卸旧电灯泡以获得金属套管。我建议戴着这部分的安全手套。

- With a hot soldering iron loosen the connection on the side of the bulb and the bottom point.

- 挥动玻璃一点应该从粘合剂中松开它。

- Pull out the old glass bulb from the metal casing and then using a screwdriver clear out the remaining adhesive in the metal casing.

第6步:制作新的LED灯泡:

This is the easiest way for me to make an led bulb without having to make changes to the flashlight.

- Find an old capacitor from salvaged pcb's it needs to be 8mm in diameter to work, open it up from the lead side and remove the innards. We just want the aluminium case.

- You'll need a small <3cm piece of wire that's less than 1mm thick and has a decent amount of copper wire.

- 从电容器侧的顶部制作一个约1-2毫米的小孔。我用了一个钻井,刚用手钻了它。孔需要足够大的电线适合通过。

- Now using thermal glue or CA glue stick the LED on top of the capacitor shell making sure the positive leg is facing the hole.

- 通过孔喂电线并将其焊接到LED的正腿上。

- 将一些热胶或CA胶水放在电容器的基部周围,然后将其推入旧电灯泡金属壳体(旋转,使负腿与金属壳体中的凹槽一致),并带有底部孔的正线灯泡套管和焊接焊接到位,留下一块漂亮的焊料,良好的电气连接。

- 焊接一根电线(我使用从电阻器腿上留下的过量)在LED的负腿和金属壳之间。

这就是现在你有一个适合任何普通灯泡插座的LED灯泡。

第7步:组装升级的Maglite:

Now all that's left to do is to reassemble you flashlight.

I used some adhesive backed foam on the sides of the battery holder to stop it from rattling in the flashlight.

您需要堵塞您的手电筒,并使它第一次使用它来重置保护电路时充电。

在设计中,我制造了循环,在那里您可以将电缆绑在一起,作为拉动选项卡,当您想要卸下电池座时。

Step 8: Enjoy!

Now you can enjoy your new upgraded flashlight and never have to worry about having to replace the batteries again!

With the 1 watt LED I get about 8 hours of runtime with a 2 hour charge to full.

如果您有任何疑问,请在下面发表评论。

幸福的制作!

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    32评论

    1
    JGJMatt

    9天前回复

    你好!
    你绝对可以,只需确保它是一个(3.7V)的正确电压

    1
    Hovells10.

    9天前回复

    谢谢!

    2
    scottsdalejim

    Question9天前Step 8

    Did you test the light output (before and after conversion)? If so, what was the improvement?

    1
    JGJMatt

    回答9 days ago

    你好!
    在像这样的1W转换上,像这样的输出,它是一个更均匀的光束。我也在我的一只杂草上做了10W Cree转换,并且完全亮起邻里!

    1
    BM1984

    9天前回复

    关于10W转换的快速文章的任何机会?

    1
    JGJMatt

    9天前回复

    不幸的是,我目前没有组件,但基本上改变的是你删除了交换机的“灯泡部分”,以便更多的空间,然后您需要一个适合身体的散热器,用CC模块更换电阻器修剪反射器一点。
    I will definately do one in the future.

    1
    Amycurlings183.

    Question10天前介绍

    你好!你知道是否可以改变任何东西以使用MAG Lite XL50吗?

    1
    JGJMatt

    回答9 days ago

    Ok I've had a look at some pictures and what I would personally do is to modify the original battery housing so that instead of 3xaaa batteries it holds a single rechargeable CR123a Li-ion, this should give you comparable runtime and quick recharges. Unfortunately without having the flashlight I won't be able to design something for you, but it should be pretty straight forward.

    0
    JGJMatt

    回答9 days ago

    嗨,我会看看,让你知道。

    2
    curiosity36

    10 days ago

    "I was lucky enough to get a bunch of Maglite 3 D-cell flashlights from my local metal recycler." Lucky indeed!
    聪明的转换。尽管有CC缺点,如果在这种情况下,它就是一个,我喜欢吻概念。“一切都应该尽可能简单,但没有更简单。”- A.爱因斯坦
    A well presented Instructible. Thanks for sharing.
    1 Watt LED flashlight lamps available in the market place. Although, they will add to the cost. Here is an example.
    https://www.superbrightleds.com/moreinfo/miniature-and-subminiature-bulbs/1-watt-flashlight-bulb/372/Posted as info only. I'm, in no way affiliated with this company.

    0
    JGJMatt

    9天前回复

    非常感谢你!
    是的,那天我幸运的是,我们当地的警察局扔掉了所有的手电筒。我喜欢在我的高功率构建上使用CC模块,但在这样的东西上,我认为电阻只是精细,并且肯定更可靠。

    1
    rhill85053

    10天前介绍

    Law enforcement used the mag lite in years gone by. They quite because of the batteries running out of power and the weight. The size/weight could be used as an additional weapon, if needed. The battery life was unacceptable. You have resolved this scenario by using an LED light! Good job.

    0
    JGJMatt

    9天前回复

    你好!
    Ironically that's exactly what happened, it was brought to the salvage center by our police. A lot of my maglites still have our local "South African Police Service" logo on. Another problem I saw was more than 70% had badly corroded batteries inside.

    1
    abacab64

    10 days ago

    在我看来,这是一个很好的项目,我们不得看看物体的成本,而是激情和工作的赞美

    0
    JGJMatt

    Reply 10 days ago

    非常感谢你。

    2
    Johnw51.

    13天前

    我想你可以买一个相当良好的LED手电筒,比你在这个项目上花费的相同或更少的价格,但嘿,那里的乐趣在哪里?做得好!

    4
    贝美菲尔

    Reply 13 days ago

    约翰,我同意你的看法。但JGJMATT展示了一个美丽的项目。有时成本是次要的越野旧项目的乐趣和乐趣

    1
    NIC.BRYAN.73

    Reply 10 days ago

    Plus, this way you get to keep the aluminum nightstick part of lugging around 2-7 D-cell batteries in an aluminum tube.