[PSUBS-MAILIST] LED Lights

Tue Jul 21 22:54:12 EDT 2015

Alec, on the work we did on the 5000 lumen LED, you had to be very careful
that you designed heat sinks in the housing to dissipate heat  or the
manufacture solder joint would fail.  The 5000 lumen  Vero 18 has a
diameter of 3.6 cm.  The Vero 29, is 4.9 cm or only about 40% larger.  My
major concern on packaging 4 of these little beast in one housing is that
it is going to pull quite a bit of power and generate a lot of heat to
dissipate.  Even though you would save money on connectors as you say,
I would like to see us stick with one Vero 29 arrays per housing to make it
easier to deal with the heat and keep from drawing so much current.  Also
with the smaller housing,  if we limit the max depth of say 1000 fsw, it
would be easy to handle the pressure with a 1-atm housing.  Also if we
stick with one Vero 29 array per light, we can design the light so that it
won't have be submerged to operate.

The 5000 lumen light I have will blind you.  Can't imagine what a 10,000
lumen version would be like let alone a 40,000 lumen light!

Not locked to anything at this point.

Cliff

On Tue, Jul 21, 2015 at 8:59 PM, Alec Smyth via Personal_Submersibles <
personal_submersibles at psubs.org> wrote:

> I was not familiar with the Vero 29 but just looked it up and I see it's
> under 5cm in diameter and less than 2mm thick! Wow, that means we're
> talking about a really small little device despite the hefty lumens output.
> Since the packaging is so small, and given the current draw is about 4
> amps... do you guys think it might be worth making an array of four of
> these Vero 29s into each light? The cost of machining would likely not be
> that much more, and the cost of the Subconn connector identical, so it
> might be quite a bit more economical per lumen to go with a little array of
> four. It would be a ridiculous number of lumens, ridiculous is good in this
> case and we're still at a size that would fit very easily on any sub.
>
> A first stab at housing decisions, not very premeditated:
>
> - Oil filled, so that depth rating is immaterial. In my case I would need
> it to go to 1000 feet, or more if I wanted it to go on the sub during a
> depth test.
> - Aluminum housing, for ease of machining and corrosion resistance.
> - Flexible plastic lens, to act as a compensation bladder for thermal
> expansion.
> - Subconn connector, not because you need the pressure rating but because
> it will keep the oil in reliably!
>
> Just some initial ideas, I don't own the truth.
>
>
> Best,
>
> Alec
>
>
> On Tue, Jul 21, 2015 at 8:34 PM, Clifford Redus via Personal_Submersibles
> <personal_submersibles at psubs.org> wrote:
>
>> Ken/Alan/Alec/Jon
>>
>> More Thoughts
>>
>> After Jon sets up a place were we can collaborate and share files, if it
>> would be helpful, I could post the drawings I have for 5000 lumen flat body
>> 1-atm LED light and a  short video of the 5000 lumen LED in operation.  My
>> thinking is in order to fast track the project we could take this design as
>> a starting point and just geometrically scale up the housing  just large
>> enough to fit 10000 lumen Bridgelux Vero 29 and its support base.  Should
>> be plenty of room for a larger diameter PCB that Ken can design. We should
>> be able to use the same  Subconn MCBH-3MP connector.  We get a good
>> discount on Subconn connectors through Psubs.  This design uses a hard
>> anodized 6061-T6 for the housing and a 3/8" borosilicate glass for the
>> lens.  The lens was an OTS item from McMaster Carr. This design did not
>> have a reflector but it would be easy to incorporate after we settle on
>> beam angle.
>>
>> To me, the key is to work as group on the draft spec that Ken comes up
>> with.  From the housing perspective, the key items the spec needs to call
>> out are :
>>
>> 1) design depth,
>> 2) 1-atm vs  oil pressure compensated,
>> 3) housing material
>> 4) type of electrical penetrator
>>
>>  I have Autodesk Inventor Professional loaded on my PC.  Using feedback
>> from the group I can use Inventor to generate fabrication drawings an do
>> the FEA work. After we freeze the design, we take Alec up on his offer to
>> machine the housing.  If for any reason, he can't , I can use the machine
>> shop I work with to machine the housing. After we have the prototype, I can
>> test it in my test chamber.  For those that don't have Inventor, Autodesk
>> has a nice 3-D viewing software that the team should be able to download
>> for free and to view and critique design iterations.
>>
>>
>> Cliff
>>
>>
>>
>>
>>
>>
>>
>>
>> On Tue, Jul 21, 2015 at 6:15 PM, Alan James via Personal_Submersibles <
>> personal_submersibles at psubs.org> wrote:
>>
>>> Hi Ken,
>>> a few thoughts once you have settled on the
>>> electronics are.....
>>> Do we want a hard anodized aluminium housing?
>>> Do we want the housing oil filled?
>>> What sealing configuration do we want?
>>> What beam angle do we want?
>>> What sort of reflector?
>>> What sort of lense?
>>> How are we going to seal the cable coming in to the housing?
>>>    Some of these answers may be dictated by what is available off
>>> the shelf at a reasonable price.
>>> Cheers Alan
>>>
>>>
>>>   ------------------------------
>>>  *From:* Ken Martindale via Personal_Submersibles <
>>> personal_submersibles at psubs.org>
>>> *To:* 'Personal Submersibles General Discussion' <
>>> personal_submersibles at psubs.org>
>>> *Sent:* Wednesday, July 22, 2015 5:16 AM
>>> *Subject:* Re: [PSUBS-MAILIST] LED Lights
>>>
>>> The electronics and custom PWB won’t be the issue. Figuring out what we
>>> want may be the biggest problem.
>>>
>>> Ken
>>>
>>>
>>>
>>> *From:* Personal_Submersibles [mailto:
>>> personal_submersibles-bounces at psubs.org] *On Behalf Of *Clifford Redus
>>> via Personal_Submersibles
>>> *Sent:* Thursday, July 16, 2015 3:52 PM
>>> *To:* Personal Submersibles General Discussion
>>> *Subject:* Re: [PSUBS-MAILIST] LED Lights
>>>
>>> Alan, we have a lot of collective experience we could use on the
>>> project.  I really love the fact that Ken is an EE with experience LED
>>> drivers.  After we agree on specs and packaging I am sure he can design a
>>> custom PCB for the electronics.  Having just gone through the exercise of
>>> designing a 1-arm housing, I don't think it will be difficult to design the
>>> housing.
>>>
>>> Cliff
>>> On Thursday, July 16, 2015, Alan James via Personal_Submersibles <
>>> personal_submersibles at psubs.org> wrote:
>>>
>>> Cliff,
>>> I'm on board with the LED light project.
>>> Have done a bit of experimentation & bought about 10 different LED
>>> flashlights, underwater flashlights, flood lights & various lenses.
>>> I also have a friend whose working involves running banks of LED
>>> lights on advertising hordings, if we get stuck on the technical side.
>>> Alan
>>>
>>> ------------------------------
>>> *From:* Clifford Redus via Personal_Submersibles <
>>> personal_submersibles at psubs.org>
>>> *To:* Personal Submersibles General Discussion <
>>> personal_submersibles at psubs.org>
>>> *Sent:* Friday, July 17, 2015 2:15 AM
>>> *Subject:* Re: [PSUBS-MAILIST] LED Lights
>>>
>>> Ken, I have been off the list for some time due to work and due to my
>>> email service not passing through psub emails.  I had to go to a gmail
>>> email account to get back in the loop.
>>>
>>> I am in on your suggestion to build LED psub light based on the
>>> Bridgelux Varo 29 (BXRC-50C 10K0-L-24) .   I can help on the housing design
>>> and I have access to a machine shop to fabricate the housing. I also have
>>> test chamber we can use to qualify the prototype.  Maybe we could pick one
>>> of the DeepSea Power and light LEDs take its specifications and tweak to
>>> fit a typical psubs application.
>>>
>>> We would probably need to set up something like Dropbox location,
>>> accessible to all that want to participate in the design, fabrication and
>>> testing to keep from swamping the PSUB  list.
>>>
>>> I have a function LED subsea light that works fine but would like more
>>> lumens.  It is a 5000 lumen light but would like a 10,000 lumen light.
>>>
>>> My suggestion is for you take the point since you came up with idea.
>>> Maybe we could canvas the site and see would be interested in working on
>>> the project as a first step.  Given your background in EE, maybe you could
>>> come up with a first pass at the specification and we can comment on it.
>>>
>>> Cliff
>>>
>>>
>>>
>>>
>>>
>>>
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>>
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