The show I'm currently working on has a lot of illuminated props for its Bollywood section. I'm not sure who built them, but while they did a reasonable job, their knowledge of Battery technology and protection is not quite 100%.
The illuminated umbrellas use some simple 12V tape with alternate RGB LEDs for a multicolour effect. They are powered from three LiPo cells in series to give the required 12V via a momentary action switch cunningly positioned on the shaft to be operated when the umbrella is pushed up. (Not reliable.)
The cluster of three cells have the wires soldered directly to the ends (no tags), no overvoltage, undervoltage or balancing circuitry and no overcurrent protection. The charging circuit is just a two pin socket connected across the three cells. I've not seen the actual chargers themselves yet.
Apart from all the things mentioned above, the wiring and cells themselves are bunched inside the web of sharp metal that forms the umbrella frame, and to make things worse, during the show they are thrown into piles by the performers as they exit the arena. I'm surprised there hasn't been a melt-down yet.
Despite all this, the main issues we've had with the props has been the failure of the tape due to the amount of flexing and abuse it gets. Most of the repairs have been done by military personnel, but when they get overloaded with broken units or the VERY broken ones we get a bag of them sent up to us to fix.
While the person who made these has done a reasonably good job, and spent a lot of time on them, there are a few improvements I'd make. I might use a different battery technology, pop the charging connector out of the tip, maybe relocate the power supply and switch down to the handle area and include short circuit protection in the form of a PTC fuse.
We whimsically refer to the props as Brollywood.
The illuminated umbrellas use some simple 12V tape with alternate RGB LEDs for a multicolour effect. They are powered from three LiPo cells in series to give the required 12V via a momentary action switch cunningly positioned on the shaft to be operated when the umbrella is pushed up. (Not reliable.)
The cluster of three cells have the wires soldered directly to the ends (no tags), no overvoltage, undervoltage or balancing circuitry and no overcurrent protection. The charging circuit is just a two pin socket connected across the three cells. I've not seen the actual chargers themselves yet.
Apart from all the things mentioned above, the wiring and cells themselves are bunched inside the web of sharp metal that forms the umbrella frame, and to make things worse, during the show they are thrown into piles by the performers as they exit the arena. I'm surprised there hasn't been a melt-down yet.
Despite all this, the main issues we've had with the props has been the failure of the tape due to the amount of flexing and abuse it gets. Most of the repairs have been done by military personnel, but when they get overloaded with broken units or the VERY broken ones we get a bag of them sent up to us to fix.
While the person who made these has done a reasonably good job, and spent a lot of time on them, there are a few improvements I'd make. I might use a different battery technology, pop the charging connector out of the tip, maybe relocate the power supply and switch down to the handle area and include short circuit protection in the form of a PTC fuse.
We whimsically refer to the props as Brollywood.
I kinda like the idea of a dab of hot glue across the joint, both front and back, to keep the joint from flexing. Given enough prep time, start with wires across the solder pads. Also, E-6000 is a silicone based product that holds up astoundingly well. And it launders very good! I buy it whenever I see it, especially in the smaller size.
Bollywood in Scotland? Eeh gad what has the world come to. 🙂
I was just relaxing at the hotel yesterday and I watched some dancing stuff at BBC. I was thinking of gagnamstyle for some reason.. But didn't catch quite where I got it from. And then this umbrellas come up, and I remembered. "Damn this is where this bigc is". The world have got so small..
love your videos keep up the good work.if you don't mind me asking what do you do for a living. thanks
If they short circuit the wire will become a heater. Set fire to the umbrella. Drip melted plastic onto the billy wood actors face.
You get all the good jobs..lol
A lot of those cells have protection in them. Whilst I wouldn't rely on it, it's something at least…
So there's an unplanned fireworks show in the Bollywood section then? 😛
It'll be just more glamorouser when the wires short out and you have flaming umbrellas of smoking lithium death and disappointment! 🙂
Magnets and reed switches may have been a better solution if you only want them on while the umbrella is erect
that is very crudely made.
They are totally in your face, kamp, tacky, glamorised and as a gay man I want one.
What types of failures are you seeing with them? Problems with the switch?, the wires / solder joints?
Huh? You joking right? They actually use that configuration? No protection what so ever?
Here in the states they would not be allowed to use those on stage at all.
Very quick.
thank you