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Portable (morsing) 100W led flashlight

A monster flashlight containing a 100W 8500Lm led with big heatsinks and batteries. With morse function to tell the night goodbye.

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This project was created on 07/06/2014 and last updated 2 months ago.

Description
This is a very bright portable light with proper cooling and an enclosure built from an old atx psu.
Every high power led should run cool so ot os mounted on a huge heatsink and a 120mm fan blowing the air into the psu case where al the electronics are.
The original fan from the psu still runs in the same place and pulls the air out of the back.
Nothing get hot at all. Even after long use it gets only warm.

All leds need a constant current source, so i mounted a big 600W constant current boost converter in the case supplying 3,2A at >32V.
At the moment it runs on a 5000mAh 5S Zippy Li-Po.

The lens and reflector are bought in a kit and can be mouted almost directly onto the led. I needed to cut an aluminium plate to mount the led and the lens.
It is brighter than car headlights and you can hold it in your hand ;)

The morse function makes this project connected and lets you send quiet messages through the night.
Details

See it in action here in comparison to other flashlights:

And the morse function:

The light can be seen from a very wide area and is great for morsing through the night.

Components
  • 1 × 100w led
  • 1 × Constant current boost converter at least 10A input and 3,5A output
  • 1 × Big heatsink
  • 1 × Battery or power supply capable of supplying over 100w at lbetween 12v and 20v
  • 1 × Arduino For pwm and morsing
  • 1 × 12v buck converter for the fans
  • 1 × Some switches At least one for power. more optional for more functions.
  • 1 × Lens and reflector kit
  • 2 × Banana terminals
  • 1 × Thermal grease

Project logs
  • Added a morse function

    2 months ago • 0 comments

    To do something useful with the arduino in this project i added a morse function to tell the night what you think about it ;)

    It will send any text that is received via serial and return to normal brightness afterwards:

    It is possible to put the light and a raspberry pi anywhere and send messages over the internet into the darkness.

  • Power Terminals and Poti finished

    2 months ago • 0 comments

    Got the potentiometer and some high quality banana terminals fixed to the case.

    A lipo can be connected safe and everything works at high power.

    Video will follow soon.

    Next step: Video and maybe a strobe mode and a pushbutton.

  • PWM working

    3 months ago • 1 comment

    Almost all components are now stuffed into the case. Still looks awful but works great. 

    Cooling and PWM control are working fine.

    Next steps: cleaner wiring, making use of the switch and screwing banana plugs for power in and replacing the old power socket with the volt/amp meter.

View all 5 project logs

Discussions

Chaz wrote a month ago null point

Cool, I actually built one of these. a few years back. but battery powered.
Here's some pictures.(sorry they are from ebay)
http://www.ebay.com/itm/161381801587?ssPageName=STRK:MEUNSOLD:IT&_trksid=p3984.m1562.l2649

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Yannick (Gigawipf) wrote a month ago null point

very interesting design.
I am not sure if you find a buyer with this case.
Even if i like the idea. It could need some restauration ;)
Anyways the commercial 100w portable lights are often sold at way higher prices.

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