This makes a change from the usual eBay-trash work lights that I take apart. It was given to me by the local electrical utility company to check out after it failed to take a charge. (faulty charger)
The unit has a decent set of lithium cells giving about 7.2V at 4.4Ah. The charge circuit uses a buck regulator to allow a wide voltage range to charge the cells:-
http://www.xlsemi.com/datasheet/XL4001%20datasheet.pdf
And then boosts the cell voltage to two sets of four beefy LED chips in series (about 12V total) using a boost regulator to step up the battery voltage:-
http://www.xlsemi.com/datasheet/XL6001%20datasheet.pdf
There's what looks like it could be a microcontroller or dedicated management chip, but it's not got a number on it.
The PCB is quite complex, but it allows the internal battery bank to be charged from about 10V up to 30V and drives the LED array at a constant current for its full discharge giving consistent intensity until it suddenly cuts off. I'm not keen on that sudden cut off bit, given that the guys using it are working on high voltage powerlines and equipment. But they probably have LED head torches too.
If you enjoy these videos you can help support the channel with a dollar for coffee, cookies and random gadgets for disassembly at:-
http://www.bigclive.com/coffee.htm
This also keeps the channel independent of YouTube's advertising algorithms allowing it to be a bit more dangerous and naughty.
The unit has a decent set of lithium cells giving about 7.2V at 4.4Ah. The charge circuit uses a buck regulator to allow a wide voltage range to charge the cells:-
http://www.xlsemi.com/datasheet/XL4001%20datasheet.pdf
And then boosts the cell voltage to two sets of four beefy LED chips in series (about 12V total) using a boost regulator to step up the battery voltage:-
http://www.xlsemi.com/datasheet/XL6001%20datasheet.pdf
There's what looks like it could be a microcontroller or dedicated management chip, but it's not got a number on it.
The PCB is quite complex, but it allows the internal battery bank to be charged from about 10V up to 30V and drives the LED array at a constant current for its full discharge giving consistent intensity until it suddenly cuts off. I'm not keen on that sudden cut off bit, given that the guys using it are working on high voltage powerlines and equipment. But they probably have LED head torches too.
If you enjoy these videos you can help support the channel with a dollar for coffee, cookies and random gadgets for disassembly at:-
http://www.bigclive.com/coffee.htm
This also keeps the channel independent of YouTube's advertising algorithms allowing it to be a bit more dangerous and naughty.
The battery outputs about 8 watts, and with 3 batteries, it would be outputting 24 watts. assuming that both the LED and the boost converter have a 90% efficiency, that would be 19.44 watts, from that we can infer that the light is outputting almost exactly 20W of light.
The donut inductor, the capacitor next to it, and the diode next to it on the other side of the board form a boost converter, or maybe it is a buck converter and the batteries provide power in series at 24V, that might explain the battery balancing setup.
PS: It is refreshing to see an actual properly built circuit, although analog circuits are really cool and easy to visualize, the complex digital circuitry does the job, and it often does it a lot better job than the analog circuits can.
I'm actually surprised that this Chinese lamp was not full of big bolts and Nuts to add dead weight to make it feel beefier……
This video just popped up in my recommended, but it reminded me that I have a pile of LiPo cells that I was planning to use to upgrade a pair of work lights a bit like this.
They're German made and quite decent quality, but there's just SO MUCH empty space inside I can't NOT put bigger/more batteries in there.
You are more useful than the BBC mate.
Ahh Clive, you are polite most of the time, until you turn into the Scotsman you really are.
I love being able to save some money when I can, but I love having well made and great quality tools/electronics even more.
Knowing that something will last a very long time with daily or semi-daily uses, it's really worth spending the extra up front cash.
Chinese online retailer would rate that battery pack at 3,458,100,989 MaH.
You know you're good when a utility company asks you to try and fix stuff
Who makes the crappy Chinese one? Unekonomical?
Got both extremes there lol… One is over complex for what it is, the other barely worthy of the chassis it's put in. I'm not sure why a simple light needs a microcontroller, but at least a real battery with conversion long beats a single cell and a resistor 🙄
I like the way he takes the cheap one out of view and there is a junky crashing sound.
Stuffed with batteries Clive hahaha ya right
Know to buy that model now🇨🇮☘️