LED constant current drive flashlight

The LED flashlight + mobile power function design of this project is realized by pure hardware. SW6106 is responsible for charging the battery and providing fast charging input and output functions for the TYPE-C port. The high-power LED constant current drive power is obtained by another output interface of SW6106 through CH224K to deceive the 12V1.5A 18W output, and then the LM358 op amp samples the voltage through the shunt resistor and compares it with the reference voltage to control the NMOS switch to realize the hardware adjustable constant current function. 
Since high-power LEDs generate a lot of heat when working, ordinary passive cooling can no longer meet the needs, so this project uses active air cooling to collect the heat sink temperature in real time through the NTC thermistor. The hysteresis comparator built by the LM358 op amp controls the fan power switch to control the LED heat sink temperature.
 
Function parameters
1. The battery is charged by two 18650 in parallel 4A high-efficiency switches 18W high-efficiency synchronous boost output (can only be in one working mode at the same time)
2. Type-C Support PD3.0/PD2.0/QC3.0/QC2.0/FCP/PE2.0/PE1.1/SFCP fast charge output, support PD3.0/PD2.0 fast charge input3
. One high-power LED constant current driver (maximum 12V 1.5A 18W) One low-power LED constant current driver 4 LED power indicators and 1 fast charge LED indicator4
. 1 high-power LED control button (long press the button to turn on and off the output) A dial potentiometer (control the LED brightness) 1 low-power LED control button (press to light up and not press to turn off)
5. 12V 2006 (20*20*6.2mm) fan driver NTC temperature>40° to turn on the fan NTC temperature<30° to turn off the fan6
. Standby power consumption is about 40uA. When the 6000mAh lithium battery is fully charged, the 12W LED power is fully turned on and the battery life is about 100 minutes   .
 
Device information1
. The final product is mainly composed of: Shell + PCBA + two 18650 batteries + LED light board + focusing lens + heat sink + 2006 fan + dot laser head + M2 copper column and flat head screw
2. The length, width and height of the finished shell: 120*49*25mm, respectively composed of shell 1 and head cover 1, fixed by 4 M2*5 flat head screws, produced by Jiali Chuang 3D printing
3. PCBA: double-layer board 1.6 board thickness consists of two independent PCBAs connected together by 4 M2*4 double-pass copper columns and 8 M2*3 flat head screws (pay attention to the direction)
4. The 18650 lithium battery uses a normal 4.2V voltage by default. If you need to use a high-voltage lithium battery, you need to change the SW6106 related configuration resistor. The higher the capacity, the longer the battery life
5. The LED light board is composed of lamp beads and heat dissipation substrate. The width of the lamp board is <19mm, the height of the lamp wick is <1mm, and the lamp beads must use a flat head package, otherwise the focusing lens cannot be installed. As long as the size parameters are suitable, any lamp beads can be used.
6. Due to the structural design of the head cover 1, the focusing lens can only use a 12*6mm diameter borderless lens. Try to use glass material.
7. Due to the structural design, the heat sink can only use a 22*22*20mm heat sink. The LED light board can be fixed to the heat sink through thermal conductive silicone and thermal conductive double-sided tape. There are direction requirements when installing.
8. 2006 cooling fan length, width and height: 20*20*6.2mm. The size can be small but not large. 12V power supply. When installing, the cooling fan wire should be installed first. It should be led out through the shell bayonet.
9. Laser head size: diameter 12mm height <20mm output: 3V~4.2V maximum constant current 160mA power supply. The color is arbitrary. It does not have to use a laser head. It can also drive other low-power LEDs.
 
Purchase reference
1. The LED light board I used was disassembled from the projector lamp. It seems to be the XHP50D lamp bead. I haven’t seen it online. Pay attention to the lamp bead voltage, power, packaging and substrate size. Any lamp bead can be used if the parameters are suitable.
2. Focusing lens: https://m.tb.cn/h.URlB8qP?tk=PnWUddMsYJw
3. Heat sink: https://m.tb.cn/h.URlBhLm?tk=c3MbddMIdLp
4. Cooling fan: https://m.tb.cn/h.URlB3RJ?tk=W1FuddMIzUn
 
Notes
1. When charging the battery or charging other devices, the high-power LED cannot be used and will automatically turn off 
2. When assembling, first install the head cover part and then solder the wires to the PCBA for final assembly. Try to use high temperature resistant materials for 3D printing shells 
3. PCB thickness 1.6mm Component parameters are based on schematic parameters Some component parameters need to be recalculated according to the devices used Hardware information and shell design information are in the attachments 
4. This project is relatively complex and novices are not recommended to make it themselves Compared with the works in the demonstration pictures, the open source designs have been partially optimized and improved