Led Ring Light DeskLamp Conversion

thingiverse

In my past projects, I've successfully converted an inexpensive halogen desk lamp into an LED conversion, but it lacked the necessary brightness and variability to meet my needs. I designed this replacement lamp head around a set of LED ring lights that I found on eBay, which were originally intended for automotive use. Their potential uses went far beyond their original purpose. This project is a large-scale print, requiring both area and time. It's not for the faint of heart. The electronics needed to drive and control it are still in development. Check out this object for a smaller version: http://www.thingiverse.com/thing:1845911 My concept involves "stepping up" brightness by gradually turning on more LEDs, providing a range of 11 steps (in my design) of adjustable brightness. The four ring lights have diameters of 90mm, 110mm, 130mm, and 150mm. I found the donor lamp base at a thrift store for a steal. It features 6mm extendable rods with a double D end for transmitting power from the base. My electronics are based on an Arduino MiniPro and a 4-channel FET switch board (see eBay link). I also needed a rectifier/filter board to convert AC power to raw DC, as well as two small regulators – one for the LEDs (12v) and another for the Arduino (5v). I plan to add a rotary encoder to control brightness. These parts represent what I bought; they're not the actual components: http://www.ebay.ca/itm/Four-Channel-4-Route-MOSFET-Button-IRF540-V2-0-MOSFET-Switch-Module-For-Arduino-/171915397754 http://www.ebay.ca/itm/KY-040-Rotary-Encoder-Module-for-Arduino-AVR-PIC-/401150412050 http://www.ebay.ca/itm/Car-Angel-Eyes-Halo-Ring-Fog-Headlight-White-Light-2x-90mm-1210-3528-24-LED-/172265849655 I made the head shell a bit larger than it probably needed to be, as I wasn't sure of the required volume. This project is still in progress and may require redesigning the shell. I added the "schematic" – a quick hand-drawn diagram – along with my current Arduino code. It's functional and responsive but takes a second to boot up. I'll address this issue when time permits. I also included the little PCB holder I used for my project; you may need to design your own to fit your needs. The encoder didn't have a mounting hole, so I used a soldering iron (around 430F or 220C) to "make" a hole in the shell where I wanted it mounted. Use an old iron tip. Printer Settings: * Printer: Mendel Max 1.5 * Rafts: Yes * Supports: Yes * Resolution: 0.3mm * Infill: 15% * Notes: Print the ring support head with the concentric slot side up and using supports for the square pocket at the back. The head shell print was time-consuming, printed hollow-side down on a raft with pillar supports – it's the longest print I've done to date. Removing the support material wasn't fun. I used 2 perimeters on both objects, which turned out okay. Be careful when trimming and removing support material – that's all I'll say about that. Post-Printing: When removing support from the double D slots for the rods from the base, be cautious not to clear too much plastic. I added a flat washer under the screws for the rod wire connections to spread the load on the plastic. The LED rings fit snugly into the head's grooves and are held in place by small dots of RTV silicone around the rings (don't overdo it with the silicone). Wires pass through the hole back to the electronics and power. A set of M3 15mm cap screw washers and nuts hold the shell to the head, secured with a few drops of silicone. When I have more details, I'll post additional information – again, this project is still in progress.