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This page is currently being used to document the build of my dive torch. The prototype of this torch is my bike light, information on which can also be found elsewhere on this site. The light head is milled out of a solid block of aluminium, and includes seven high power LEDs, putting out a lot of light. |
This light is designed to be usable down to depths in excess of 100m, and I hope to test this in a pressure pot soon. The prototype has been taken on a dive to 70m without any problems, but much of my diving is considerably deeper than 70m, so I really want it tested to around 15bar!
My current dive torch is a Custom Divers 10W HID, and I wanted to produce a torch that would be closer to an 18W HID torch, but small and robust. The prototype bike light is significantly brighter than my HID, and is using LEDs that are significantly less efficient than those currently available, so this one should be bright!
Once this light is complete, I'll write it up properly, but for now, here's some pictures of the production. More information on the design can be found on the Bike Light page.
The above picture presents an exploded view of the main mechanical parts of the light. These are -:
- The main body
- The front bezel which holds the 4mm front glass
- The button
- The button retainer
- The handle
Not shown are the electronics, the LEDs, bolts, cable gland and button spring.
The following pictures show the light being produced...
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The light head is milled out of a solid block of 6082 aircraft grade aluminium on my CNC mill. The mill is a low cost mill/drill that I converted to CNC operation. |
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7 CREE LEDs in a very small space generates a LOT of heat, and without proper thermal management, they will burn out. It's extremely important to be able to get the heat away from the areas where it's being generated, and out of the case as efficiently as possible. The LEDs are mounted onto a home made Metal Clad PCB (MCPCB). This is made in two parts - an aluminium holder which will contact onto the thermal pad on the back of the LED, and a PCB which is milled to fit inside the recess in the aluminium which provides the electrical continuity between the LEDs. |
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The 7 CREE LEDs are soldered to the PCB, and the completed PCB/LED module is glued into the aluminium heatsink with thermal adhesive. |
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This shows the top of the electronics board. This holds the microcontroller and the main power electronics. The connector on the right of the board is for programming the processor and is only required for development boards. |
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This photo shows the bottom of the electronics board. The shape of the board is designed to fit perfectly into the light head, and for the high power components to be extremely close to the aluminium to allow a good heat path. The tabs on the board are designed to slot into the light head to hold it securely in place. |
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