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> LED Foglight Project
Chi-town
post Apr 24 2019, 09:25 AM
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Just a thought but if you're using a LED chip with an optic and then putting behind a standard thick fluted lens the output is going to be severely reduced. I would guess roughly 30%.

Have you put the standard lens on top of your prototype to see what happens?
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Spoke
post Apr 24 2019, 11:11 AM
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QUOTE(Chi-town @ Apr 24 2019, 11:25 AM) *

Just a thought but if you're using a LED chip with an optic and then putting behind a standard thick fluted lens the output is going to be severely reduced. I would guess roughly 30%.

Have you put the standard lens on top of your prototype to see what happens?


Not sure how the glass lens will attenuate the light from the LEDs. Once I get the first PCBs populated I'll be able to do some testing on it. The vertical diffusers of the glass lens will tend to broaden the width of the beam. The LED lenses also broaden the beam so maybe I'll have to use more of a spot type of LED lens instead of the 10192 lens and let the glass do the horizontal spreading.
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Spoke
post Apr 26 2019, 08:01 AM
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Have the PCBs in hand. Will assemble the first boards on Monday.



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Spoke
post Apr 26 2019, 08:03 AM
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Here's the PCB under the glass. It will be interesting to see how the fluted glass will diffuse the beams. The LED lens already provides some lateral diffusion.

The Boostpucks by LEDynamics also arrived. I'll probably power the first prototype with these as it will shorten the time to first light-up.


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DRPHIL914
post Apr 26 2019, 08:06 AM
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(IMG:style_emoticons/default/popcorn[1].gif)

Looking good! Cant wait to see them in action!

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Spoke
post Apr 29 2019, 01:55 PM
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Things like this happen when you set the temperature profile wrong on the infrared oven.


@mepstein I have your foglight board. Not sure why it doesn't light up but I'm working on that. (IMG:style_emoticons/default/beerchug.gif)


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mepstein
post Apr 29 2019, 02:14 PM
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QUOTE(Spoke @ Apr 29 2019, 03:55 PM) *

Things like this happen when you set the temperature profile wrong on the infrared oven.


@mepstein I have your foglight board. Not sure why it doesn't light up but I'm working on that. (IMG:style_emoticons/default/beerchug.gif)

That looks more like when I try to do electrical work.
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Spoke
post Apr 29 2019, 03:06 PM
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With the correct settings, the oven worked fine.

BTW Mark, this one is mine.



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Spoke
post Apr 29 2019, 03:10 PM
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All lit up with LED lenses. Won't be able to compare light output until night. Also want to compare with original bulbs.



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Spoke
post Apr 29 2019, 03:13 PM
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Printed a jig to drill the heat sink for tapping. Will be using 6-32 x 3/8 stainless cap screws.



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Spoke
post Apr 29 2019, 03:43 PM
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Here's the light pattern with 0.5A per LED on the ceiling w/o the glass lens. Basically what the manufacturer said it would be.


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Spoke
post Apr 29 2019, 03:46 PM
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The glass lens fits nicely with the printed spacer. I believe the earlier lenses have a deeper cavity.



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Spoke
post Apr 29 2019, 03:48 PM
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Here's the light pattern with 0.5A with the glass lens. The effect of the glass diffusers can be seen.

As Chi-town mentioned, there will be some loss of light because of the glass diffuser. It seems to be about 15%.

With 0.5A at 1 meter, I measure:

10000 Lux w/o glass
8500 Lux w/glass

At 0.35A at 1 meter:

6000 Lux w/o glass
4500 Lux w/glass



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Spoke
post Apr 29 2019, 04:49 PM
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Redesigned the spacer rings so the boards can screw into them. This is how they will be assembled.


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Spoke
post Apr 29 2019, 04:51 PM
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These are the wrong screws. These are #4 x 5/16 whereas the correct screws are #2 x 1/4. They'll do for now.


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Spoke
post Apr 30 2019, 04:10 AM
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The first fully built up PCB. Somehow I managed to not order the correct caps for input and output filtering so had to use smaller lower voltage caps. Original caps should be 100V whereas these are 50V.

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Spoke
post Apr 30 2019, 04:15 AM
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Started doing some burn in on the first unit. Will run this for a couple of days to make sure it works. The LEDs are running 0.5A and the total unit power dissipation is just under 14W or just about 1A at 14V input.

Comparing the light output with the headlights on my '14 328, these are less than 1/2 as bright. The headlights on the 328 measured 19000Lux at 1 meter whereas this unit measured 8700Lux with the glass lens.

From early measurements, it looks like there's about a 40C rise in temperatures over ambient. That's about what I expect. It will be interesting to get this in an enclosure and see what happens.



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DRPHIL914
post Apr 30 2019, 05:54 AM
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Looks great!!! Cant wait to get a set!!
That a lot of R&D time invested in these, but looks like it will be worth it
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jkb944t
post Apr 30 2019, 06:15 AM
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QUOTE(Spoke @ Apr 30 2019, 06:15 AM) *

Started doing some burn in on the first unit. Will run this for a couple of days to make sure it works. The LEDs are running 0.5A and the total unit power dissipation is just under 14W or just about 1A at 14V input.

Comparing the light output with the headlights on my '14 328, these are less than 1/2 as bright. The headlights on the 328 measured 19000Lux at 1 meter whereas this unit measured 8700Lux with the glass lens.

From early measurements, it looks like there's about a 40C rise in temperatures over ambient. That's about what I expect. It will be interesting to get this in an enclosure and see what happens.


This is so cool, I am really enjoying seeing your progress on this project!

Jeff B
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Spoke
post May 3 2019, 07:59 PM
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Burned in the prototype for about 20 hours this week. It still works so that's a good start. With little airflow, the PCB temperature was about 50C above ambient. It will be interesting to see what the temperature rise is when operated in the case.

Put the LEDs in the case. To center the glass lens and LED board, some clips were printed to hold the board while the clips are installed.

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