Custom headlight and taillight (VESC)
I could join the discord and post it there but like... that'd mean being in the discord so instead I'll drop some info here.
Da linky https://ln2.cool/
As some might know I've been working on a headlight to go into the ELM box. This being an XR compatible controller housing to contain a VESC and other misc components you may want to contain to build your desired board.
A custom headlight is needed because the final iteration of the box isn't compatible with the existing XR headlights. Not getting into that here since my model does support it but I've been doing some work to make something that will fit in the current version and also be possible to use elsewhere.
I'm about ready to send off for a final revision but waiting on parts to be in stock. below is a look at the CAD for the design.
There are 17x 5050 LEDs, RGBW so that they will be bright enough to be useful (more so than the Pint). I tested an earlier version with just RGB since I had those laying around and they worked really well in my prototype housing (early design that wasn't the final version).
The holes for wiring on the ELM box is only 7.5mm x 4.5mm so although the footprint on the PCB has 2x JST-PH 3 pin connectors you won't be able to fit those through the small ELM housing holes so I recommend soldering directly to the holes. JST-ZH would fit but they have a 1amp current limit and that's pushing it close to the draw with just RGB leds.
The need for through-hole is in turn why the LEDs don't go all the way to the edge since having through-holes underneath an LED is a recipe for disaster and I'm not sacrificing safety for a full length of LEDs where those extra 2 will do basically nothing. I take safety EXTREMELY seriously when making stuff others are going to use. I'm not out here making hotglue time bombs >.>
An additional feature is the ability to daisy chain these. I added Digital Out (DO) on the opposite side so you can in theory program the power button off this too or wire the taillight off the DO... whatever you choose I haven't seen the VESC LED app yet but figured the option would be appreciated.
Here's some video of them being tested with only the RGB version of the LED :)
I'm waiting on stock for the RGBW LEDs to come in, then I can send off for these to be pick and placed then sent to me for additional testing like current observations, temp dissipation and fitment in the housing assuming I get one of these fancy CNC versions rather than my ancient 3D printed one from 6 months ago lol.
I did add 4x 1mm holes in the corners in a desperate attempt to have some sensible alternative mounting solution since currently some sort of thermal & non-conductive adhesive will be needed for the ELM box.
Decided to share this now ahead of asking the PCB fab to spin me up a test batch in case some big brain people wanted to chime in before MK1 V2.1 gets made. It has... kinda gone through a number of iterations and versions prior to settling on this.
I read it twice .. still don't quite get it.
@Lia, is it your commissioned work or voluntary project?
What does ELM stand for anyways? (-There's no VESC tag to this topic.)
Obviously I should've knew nothing about it, since asking stupid questions, right? lol
@sirgu Aha sorry, added the tag!
This is a custom headlight designed to go in the XR compatible ELM controller box designed to house VESC hardware.
The first batch already shipped. Some over on Reddit already have them like DoctorDugong21
is it your commissioned work or voluntary project?
I...er... honestly do not even know at this point lol. I'm getting one of the prototype boxes that were CNC'd as part of a group buy organised by @MacIak and @ed_co , the ELM name being an acronym for our names. Ed, Lia, Maclak :)
For the lights that I'm doing here we'll be selling them but I just do the design work so little if any thought about that has occurred between my last 2 functioning brain cells yet. Waiting on part stock so I can ask the PCB fab to make the PCB and solder all the components on for me since like doing these by hand suck. It takes me ages!
Thats pretty cool! Making me want to jump back into my own LED project and finish it!
also, I'm going to assume the discord is a long story...
@loaffette Good luck :) Love to see more projects~
I don't like being in Discord groups. Too busy for my tastes and I like being able to just vanish in my own space. Discord kinda just invades what free personal time I get.
@lia ah, understood!
I know a few girls who don't like discord because of..
@loaffette That’s another big one although I’ve not had issues in the OW community minus a few forward comments now and then.
@lia h o l y c r a p
Cmon gimme LEDs faster >.>
LEDs are in stock and I've been able to send off for a batch of 20 Headlights and Taillights.
It's not cheap but Nick has offered to help :3
I found some double sided adhesive thermal tape and on my test box it's holding really well and sinking the heat perfectly. After an hour doing a burn in test it's not even warm so I'm happy to assume it's unlikely these LEDs will cook themselves.
So the Headlights will come with some adhesive applied to the back of them so they can be easily installed.
The pads for wiring will be left untouched so the end user can just solder on their own connecter so that they can cut it to length and have them go to a connector of their choosing.
POV: me waiting on my bank to send me a new debit card
Look what showed up earlier for me to test in?
Edit: Just had the production file confirmed too. 8 per PCB, ordered 5 lots so 20 full sets :)
These will be V-cut into the individual headlights once the components are placed :3
@lia this looks so cool!
Had a small hiccup with the design.
Turns out the footprint for the 5050 LEDs were rotated 180 out of order compared to the actual footprint. The fab told me they couldn't just rotate the pick and place operation so I've had to re-submit it after making an amendment to the EasyEDA library for that component in hopes it doesn't trip anyone else up lol.
Just confirmed the pick and place pre-production file so ideally I should have these in a few weeks :)
Then it's a case of getting a set off to Ed and Maclak before looking to sell off the first batch. No idea on what I'll price these at yet, something sensible of course though.
I have 20 pairs manufactured currently since that made the most economical sense taking into consideration shipping costs balloon after you hit around 1.5kg total weight.
Still waiting on the lights, but they have at least touched down in the UK :)
In the meantime I'm working on the packaging since I can't just ship these things in boring boxes. No no no no nooooo~ I spent too much time in Product Design to NOT put that bit of education to use. Besides the difference between a villain and a super on is presentation and I simply cannot settle for less.
This is one of the lids to the boxes I've decorated with a stencil. I like the look (even if I got paint all over me. Thankfully not my new cute white top)
These will of course go inside actual protective postage bags and not just left bare like this.
Each of these will contain 2 headlights, one with pre-applied double sided thermal adhesive for heat dissipation into the ELM controller housing and the other will remain without.
Also included will also be 2 little transparent EML stickers because who doesn't like free stickers.
@lia -- Stunning packaging! It makes my mouth water -- although I do not even use lights on my Onewheels.
@s-leon Thank you <3 The box is a premade one for necklaces but the innards and decor will be all me :)
They're sadly not drop in replacements for the XR but rather designed for modded boards that can interface with an RGB signal (RGBW in my case)
most excellent @Lia!
@lia That's pretty cool! Can't wait to see them out in the wild!
Well look what decided to show up. So many LEDs 0.o
Work is busy today though and I'm the only one covering support so haven't been able to take pics of the test I did but they work!
Going to make a jig to separate and test these all then see how they compare to the XR, Pint and even my initial version.
Update post to follow in a few hours x