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Author My Oldham Conversions
royfellows

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Posted: 09/10/2009 14:45:13
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Hi Gang
A few results.

There’s no way I that I can get 2 X P7 emitters plus a Cree into an Oldham GT headset without the front extension. The Oldham headset tapers towards the back, plus you have a moving switch component and cables coming in.

However, I have just partially assembled a UniStar with 1 P7 and a Ledil Boom 9 degree collimator lens, plus a Cree Q5 with the usual. The replacement neoprene front seals give a bit more clearance and it all just about fits.

I am optimistic here of some impressive results. I can wire the standard UniStar belt pack 2X2 parallel and series to give the required voltage. I just add the brass connecting stud for the balance lead and it will recharge from the Maggie through the headset charger

As a point of interest, single or parallel array Li Ions off the charger driving multiple LEDs max out at about 2.2 amps. A boost circuit would be a solution, but why bother?

This lamp could give the Scurion K some serious competition on output, and at a price of less than £150, I would have to work out an exact figure.

The thing about these quad dies as I see it, the Cree X lamp is more focusable but does not have the light output of the SSC D BIN P7. I don’t know exactly what the Cree dies are, I doubt in the extreme that they are Q5s, too much heat produced for a quad.
I don’t know if anyone can add to this.


--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 89.240.116.54
royfellows

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Posted: 30/10/2009 19:23:35
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As I have gone quiet for a few weeks on this, I thought that I had better post a SitRep

The 3 X SSC P7 lamp was a sweet lamp, and gave a lot of light for watts.

I am currently working on an all new MagnumStar that uses a third switch position modification to the Oldham headset. This is not a flimsy codge up, but a brick you-know-what in the true tradition of the Oldham GT headset.
I promise some photographs and you-will-be-impressed!

The target is a lamp that gives:

Oldham SW1 Cree Q5 with good beam reflector through usual range of settings. The ‘miners’ lamp

Oldham SW2 SSC D BIN P7 through range of settings, more of a wide angle beam. The ‘cavers’ lamp.

Fellows mod SW3 rotates through 360 degrees either way for on and off, gives twin (series array) SSC D BIN P7s with Ledil Boom S collimators running at 2.87 amps, ‘power beam’
This modification means that the Oldham switch wont just rotate round and round, no great loss!

Obviously, SW3 is on/off either full rotation, so you can have ‘power beam’ plus either SW1 or SW2.

Possible maximum light output is 2700 lumens, with the use of D BIN emitters and the bit of overdrive this is not unrealistic.

I am currently using the 5 Cree MagnumStar and a lot of people have seen it in use and been impressed. Well, you have seen nothing yet.
My plan for this is to dump the problematic and noisy secondary relay circuit and also with the space saving the front extension.
Only issue is that you will get single Cree through range on SW1, or SW 2 will give the full works.
I can use a belt mount battery pack similar to the UniStar but with the Li Ion cells 2 X 2 series and parallel to get the voltage the lamp needs but the price down. Only flip side is that you would need the dedicated charger.
The way I figure it is that the size of the lamp with the front extension will put some people off, so this is a gap filler, probably be called the MagnumStar S for small or whatever.
My money will still be on it beating a Scurion K though.

No lies, I don’t do lies, there has been a lot of interest in this, sometimes emails from abroad with comments such as “not bothered about the cost”
But as everyone knows by now, it’s not about money with me. It’s interest in the job.




--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 92.28.136.130
Dean Allison

Joined: 13/01/2008
Location: Northumberland

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Posted: 30/10/2009 20:06:22
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Roy is this something you will be thinking of doing commercially? It sounds great as I am after some serious lighting for photography purposes but am not up on electronics much these days. IP: 90.203.50.159
royfellows

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Posted: 30/10/2009 20:13:27
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Hi Dean
Developments are posted to my web www.ledcaplamps.com

However, you will always get the latest here or at mine-explorer.

Thank you for your interest.

--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 92.28.136.130
royfellows

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Posted: 18/11/2009 12:31:27
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I have a lamp as described in my 30th October posting built and under test.

It certainly puts out the light, but I am wondering if I can do better with my ‘Power Beam’ using Cree MCE emitters like the Scurion uses in the K model, I may do some experimenting with these before I regard the MagnumStar as ready to offer for sale.

In the meantime, here is the clever little switch. It mounts above the Oldham switch using the terminal screws, the wires attach by eyelets under the Allen head #4 UNC setscrews.



(click image to open full size image in new window)




--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 92.28.130.183
royfellows

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Posted: 23/11/2009 12:45:26
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I have been doing some tests of the new lamp that uses SSC P7s in Ledil Collimator reflectors, and frankly the results are disappointing. At least from my point of view. I do however; feel that I have made some important discoveries.

In the week, I tested my new lamp against the car headlamps as I have done before, however the results were so disappointing as not to be worth uploading.

Basically, the new P7 lamp has no throw.

On Saturday I tested a selection of lamps in Cwmorthin, with interesting results.
I used the top chamber with the steps, and I could stand right at the back and clearly illuminate right to the top of the steps with the 5 X Cree Q5 MagnumStar I was wearing.

The 3 X P7 lamp would floodlight the chamber but the throw of it was very poor, indeed not as good as the previously tried DX 3 lens aluminium reflector unit with the P7s.

The is usually a reason for everything, and my opinion is that the answer lies in the DX reflector in as much as each reflector boring breaks into its neighbour, so in effect this gives a partial increase in size and a cumulative effect.

If one looks at the Scurion K they are using an obvious large reflector, I think that this is the answer. They also say that the P7 is not focusable, but the Cree MCE, being the one they use, is focusable.
To what extent however, is yet another question?
Some indication is given on the Scurion forum where Mr DarkPlaces states that Miles Mouldings Raptor Pro has more throw. This says much about the Scurion which purports to output 1200 lumens. For that matter is also says much about how good the Raptor Pro is!

I was there some time using the lamps to take photographs which resulted in my 3 P7 lamp being on full power for about 20 minutes. When I came to turn it off the heatsinks were very hot. I tuned it off and then unscrewed the front as being a test bed lamp it has not been sealed. Gingerly, I touched the copper plate upon which the emitters are mounted, it was hardly warm! And yet the heatsinks on the outside of the lamp were still hot to touch.

I seriously wish some had been there to witness this phenomenon, as I appreciate that it must be a lot to swallow.
I have definitely developed something interesting here.

Anyway, I have ordered some Cree X Lamp MCE quad core emitters to try. A while ago I saw one of Miles MCE torches and I was very impressed. The intention is to try substituting one or 2 of the Q5s in my 5 Cree lamp with these and see what I get.

Another interesting thing is my now awareness of the law of diminishing returns as one puts more of the same emitters on line, particularly noticeable with the 3 X P7 lamp.

1 P7 gives a powerful floodlight effect. Putting another on gives an impression of double the amount of light, which is mathematically correct as you have an increase of 100%
Putting a third gives an increase of 50%, however visual impression is of only a slight increase.

On the same token reducing the number of emitters in my 5 Q5 lamp down to 4 mathematically reduces output by 20%, visually its hard to see any difference. So substituting the centre emitter that has the advantage of the largest reflector surface with say an MCE or P7 could have very interesting results. The MCE also has the advantage of being almost the same size as an ordinary Q5, while the P7 is 12mm diameter.

Another obvious line to follow is that of reverting back to the DX 3 lens reflector with 1 Cree Q5 as a general use lamp, but the other 2 carrying SSC P7s. I may dump the idea of trying to produce a lamp for all tastes and do 2 different versions. I don’t know at this stage.


--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 89.240.162.43
SimonRL

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Posted: 23/11/2009 17:27:07
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Ta for the continuing updates Roy Thumbs Up

I suspect developing a lamp that will please allcomers is going to be a hard task. Some prefer helmet mounted batteries, some waist mounted; some prefer spill over beam, others beam over spill, some a mix of both!

What is apparent is the race for lumens, taking the Sten as an example ('cos it's the one I know best) the R70 version is quite a bit cheaper than the R100, and is itself way brigher than the old lamp, but nobody wants them, absolutely everybody goes for the R100 version.
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royfellows

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Posted: 23/11/2009 17:39:54
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I agree the race for lumens but I have to repeat what I have said before, half of it is in the optics.

Suiting everyone is a challenge, but that is what I hope to do.

The only thing is, a lamp that is ultra light and no bigger than a matchbox, but outshines car headlamps, is an impossibility at the current state of technology.



--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 89.240.162.43
SimonRL

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Posted: 23/11/2009 17:46:55
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royfellows wrote:

The only thing is, a lamp that is ultra light and no bigger than a matchbox, but outshines car headlamps, is an impossibility at the current state of technology.


Doesn't stop people expecting it Wink
IP: 83.148.135.213
Morlock

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Posted: 23/11/2009 17:56:11
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With regard to the varying requirements of the end user would a 50 millimetre version of this be practical, even if only as a clip on accessory?

http://www.made-in-china.com/image/2f0j00vMETBsCqLikOM/Fresnel-Lens.jpg
IP: 86.31.60.67 Edited: 23/11/2009 18:02:08 by Morlock
royfellows

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Posted: 23/11/2009 18:37:28
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Hi Mr Morlock
A Fresnel diffuser, yes.

This is very interesting and full of possibilities.

I am now thinking that if I can develop my lamp to give the kind of beam that, well, most of us want. One of these as a clip on would suit the cavers and photographers.

Have you tried one of these on your lamp?


--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 89.240.162.43
Morlock

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Posted: 23/11/2009 18:51:45
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royfellows wrote:

Hi Mr Morlock
A Fresnel diffuser, yes.

This is very interesting and full of possibilities.

I am now thinking that if I can develop my lamp to give the kind of beam that, well, most of us want. One of these as a clip on would suit the cavers and photographers.

Have you tried one of these on your lamp?


Hi Mr Fellows, so far I've tried a 4 inch reflector bored out to slip over the alloy heatsink/bezel of the "Redwinch" type modification, this catches a lot of the side spill and concentrates it into the spot part of the beam.
I've not found the optimum (for spot) reflector yet.

The Fresnel lens was a thought I had for a neater way to obtain a better long range performance, still in the research stage I'm afraid.

Edit: I think it will be difficult to use a Fresnel lens to improve the spot of a multi LED unit such as yours, more suitable for a diffuser I would guess?
IP: 86.10.12.249 Edited: 23/11/2009 19:09:43 by Morlock
royfellows

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Posted: 23/11/2009 19:07:41
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Morlock wrote:

royfellows wrote:

Hi Mr Morlock
A Fresnel diffuser, yes.

This is very interesting and full of possibilities.

I am now thinking that if I can develop my lamp to give the kind of beam that, well, most of us want. One of these as a clip on would suit the cavers and photographers.

Have you tried one of these on your lamp?


Hi Mr Fellows, so far I've tried a 4 inch reflector bored out to slip over the alloy heatsink/bezel of the "Redwinch" type modification, this catches a lot of the side spill and concentrates it into the spot part of the beam.
I've not found the optimum (for spot) reflector yet.

The Fresnel lens was a thought I had for a neater way to obtain a better long range performance, still in the research stage I'm afraid.


So its not a diffuser?
I would have thought that it was.
I would think that it would be a lot easier to design the lamp as a spot, and offer an add on as a diffuser, than try the other way round.

Any chance of a photograph of your slip on reflector?

What reflector are you using inside the lamp?

My best results for a spot beam are with the deal extreme cast alluminium ones.
I use their 2 lens hybrid kit in my Workstar conversion. The LED lens has a Q5 at 700mA and throws a very good beam, and I mean good. The edge is a sharp as a razor. The other lens is for a bulb, so basically does not focus an LED. I fit cheap LED as a pilot. Only problem with this kit is that you have to buy a lot of bits that are just discarded which is waste, just to get the cast reflector.

Its SKU 14600 if you want to take a look.

I have also used their 3 lens model, and their 5 is what I currently use in my MagnumStar.

Point of interest, I ordered 3 MCEs on Friday, and I see that today they are packaging ready to mail.

This must be some kind of record.



--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
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Morlock

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Posted: 23/11/2009 19:23:15
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Yes, you are correct a good spot would be a good starting point. As you can see the single Cree R2 gives reasonable spot plus a fair bit of side spill at 20 metres but could be a better at 50 metres.

20 metres.

50 metres.


These pics were of the conversion "as built", I'll get a pic up of the reflector but it's just an EverReady handlamp reflector bored out to to slip over the parallel part of the bezel.

IP: 86.10.12.249 Edited: 23/11/2009 19:24:57 by Morlock
royfellows

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Posted: 23/11/2009 19:49:32
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I am looking at your conversion.
I think you are the bees knees as an engineer. I would say that you have an SKU 14598 fitted into your housing. Or maybe an SKU 5951?

Your turning on the lath and final polishing is immaculate.

I was in the motor trade and acquired some skills as a panel beater. I work with copper as can be seen. My thermal conductors are of 12mm copper bar and beaten/shaped copper plate joined by soldering.

I have found that the ratio of surface area to mass in the conductor, relative to the cowl and heatsinks is what governs the effectiveness of the system.

My UniStar lamp, as it is, could not support any more than 2 emitters without increasing the external heatsink area.
The MagnumStar eats anything for breakfast.

It certainly works but I ponder a lot on exactly how.


--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
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Morlock

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Posted: 23/11/2009 20:04:07
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Thank you Mr Fellows, I'm always amazed at how much you manage to pack into the Oldham headpiece with your conversions.

I think my next experiment may be to machine the reflector that comes with the R2 unit to smooth polish as oposed to the light ripple effect it comes with, may improve the spot, I can then work on a diffuser.

I'm not sure which emmiter I have, got it from Ebay for £8.99 complete with the alloy reflector, (I think it's a spare for a Surefire type torch).
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royfellows

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Posted: 23/11/2009 20:30:06
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You may want to have a browse on DX, its http://www.dealextreme.com/

I am Roy to just about everyone, but don’t like calling you Morlock.
I always address posters as "Mr" as a sign of respect, because I try to be scrupulously polite. It may well just be one of my funny ways.

Moving on, I do not know of anyone on either website who is an expert on thermo dynamics, and could possibly explain the technicalities of my system.
Have I invented something new, or just discovered for myself a well known fact?
I would be very interested to know about this.

The whole thing came from the fact that I was unable to get aluminium forward extensions made for me at an economical price.
This caused me to get my brain in gear. Now look at what we are doing!

I expect to get the MagnumStar finalised shortly, and then I want to move on to photo lamps and hand lamps using the same principal.

I am going down to Devon next month and will pick up some ex navy signal lamps from a surplus stores. These will give me opportunity to develop a hand lamp. I will be working with 12 volts as it’s compatible with a motor car and want to offer a car fixing.

I have a driver setup that will power a series array of 3 quads, say P7s or MCEs. The lamp will hold 2 of these to give up to 5400 lumens.

I also have some good ideas for photo lamps using a single X2 array running off 2 X 18650s in series.

Its all interesting stuff, time is getting on and I am logging off for the evening.


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''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
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Morlock

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Posted: 23/11/2009 21:55:01
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No problem Roy, Smile feel free to call me Morlock.

Handy link, thanks.
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royfellows

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Posted: 25/12/2009 12:11:49
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LATEST UPDATE

Just for the benefit of those who are keen to see where this MagnumStar is going to end up, I have just cancelled my order for Cree MCEs with DX and reordered them from Kaidomain. These people are more expensive but I have not yet been messed about by them.
DX are showing my order as “Ready” for the last month yet they have none in stock.
KD has the latest M BINS anyway which generate even more light.

I have also ordered some of the 14mm aluminium heat sink bases intended for Q5s, the plan being to fit the bare MCE emitter to one of these and replace the centre Q5 in the MagnumStar’s cluster of 5 Q5s, so then it will be 4 X Cree Q5 plus 1 MCE. Operation of the MCE will be by the 3rd switching position modification I developed for Oldham’s.

At the MCEs drive current of 3.1 amps, and the Crees at 1.07 amps, which is a slight overdrive, I calculate the light output as being about 1750 lumen. If it works out, this is the design I will be taking to the bank.

I am also awaiting the 2 boring reflectors for the WorkStar, now down to 1 in stock, but if this becomes discontinued I can continue to produce these lamps at the same price of £50 exchange on your exiting Oldham by building everything on an aluminium disk which I can get stamped out in Birmingham. I just mount the LEDs with same reflectors as UniStar and a couple of Farnell heatsinks, no problem.

UniStar continues in production, I am accepting orders for either 10 amp hour belt mounts at £100, or helmet mount with 2 X 5 amp hour packs at £110. Postage is signed for and costs £7.

Both above run at average of 4V and recharge through any Oldham charger with output of about 5V. Home made Oldham chargers are OK as long as the output is below 6V, higher than this could damage my control circuit in the battery case.

A very merry Christmas and a good exploring new year to all of my existing and future customers.

www.ledcaplamps.com


--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 89.241.109.33
royfellows

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Posted: 08/01/2010 18:30:12
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I’m back!

I have just successfully mounted a bare Cree MCE M BIN 750 lumen quad die onto a 14mm heatsink base designed for the Q5.
I have mounted it in a DX 5 lens reflector and powered it in my hall.

It rocks

Its not the tight beam that I would get from a Q5, its about 2.5 times the beam width with a lot of spill, but it certainly puts out the light and I have to provisionally venture the opinion that it is more useful an emitter for a caplamp that the SSC P7 in any form. Basically, I would say that it is just about right for the caving community who do not want tight beams.

I sometimes struggle to control the ‘over the top’ nature of myself, but I can assure the reader that there is no intention to fit 5 of these into a caplamp and then unleash this on an unsuspecting mining community.

Sensibly, the intention is to replace the centre emitter of the MagnumStar with one of these in a redesigned model that incorporates the 3rd switch I designed. So maximum power would be 4 X Cree Q5s with a bit of overdrive, plus the MCE, also with a bit of overdrive, to give about 1750 lumen in a useful beam pattern.



(click image to open full size image in new window)

The series array P7 setup will be forming the basis for my photolamps.

And more, lamp builders read this.

I lost my temper with a troublesome keyboard late at night after about 5 cans down and smashed it into smithereens.

The next day I was continuously picking the smithereens up off the floor. A smithereen if you have never seen one is very small.

Joking aside, I stopped and looked and some or parts. In is in the form of a springy plastic cup of 14mm diameter. Basically these could be used to cover make/make – break/break button switches inside a waterproof case.
An issue solved for my photo lamps which I know people will want to lower into sumps, and possibly a lamp building solution for someone?


--

''the stopes soared beyond the range of our caplamps' - David Bick...... How times change
IP: 78.145.201.202
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