The idea of ​​how to convert a headlamp into a battery-powered one arose a long time ago, this is especially true for fishing and when. Since it is not profitable to constantly buy batteries in our age of mobile phones. So, after thinking about it and ordering the necessary spare parts, which I will describe below, I began to modify the headlamp for batteries with my own hands, using a Chinese circuit with a charger. This makes it possible to charge the battery both in the car and from a regular one. micro USB modern phone. I usually order from Aliexpress, although it is possible to find it in stores, but it’s 2 times more expensive.

A very bright and functional headlamp, for such a price, but for some reason I haven’t found one on sale now
I tried to remake this model as well, but it was a little inconvenient to install the button and the diode plate got hot, so I had to isolate it from the battery with a piece of plastic. But in the end the flashlight works properly

The flashlight was delivered to the post office in 20 days, which made me happy :) .

The idea is very simple and anyone can do it; all you need is a small battery from an old cell phone, it contains a Li-Ion battery with protection. The voltage parameters are ideal, led flashlight has a voltage range from 4.5 - 2V, and a 3.7V battery in a charged state of 4.2V has a decent capacity, which can be increased by adding another battery in parallel. You just need to correctly identify the contacts (most have plus and minus indicated), all that remains is to carefully solder the contacts so as not to melt and avoid a short circuit.
The problem with charging via a regular micro USB can be easily solved by ordering a small board costing about 20 rubles. Micro USB performs a very important role in monitoring the charging and turning off the ice lamp when the battery is discharged.

Installed on the board LED indicators, which show in color when the converted LED flashlight is charging. Thus, the modification of the Chinese headlamp comes down to soldering the wires to the terminals.
Using this board, converting any flashlight to lithium is quite simple, it is only important to know how many volts the battery produces.

Charging board, purchased in an online store with free delivery

Perhaps I ordered 10 pieces for myself at once because it is universal and can be used in children's toys.

Battery connection diagram

Board parameters

• Input voltage from Micro USB: 5V
• Charging cut-off voltage: 4.2V ± 1%
• Maximum charging current: 1000mA
• Battery over-discharge overvoltage protection: 2.5V
• Installed overcurrent protection current: 3A
• Board size: 2.6*1.7CM

In fact, this is a separate board that is used in a power bank, and if you buy an additional USB output, you can charge your phone

Let's start remaking

Exploded view of the lantern and the first stage of assembly

Now, about the conversion of the flashlight itself to use a battery instead of batteries, most flashlights use 3 AA 1.5 V in size, comparable to a mobile battery, and fits quite well in the main body, you just have to expand the seat. After simple manipulations, having unscrewed or cut out all the excess, we mount all the parts in place using hot-melt adhesive.

LED flashlight conversion diagram
Solder all the parts in place using a heat gun
If necessary, you can increase the capacity by connecting 2 batteries
We get a modernized headlamp with a mini USB input

Finally: LED flashlight Worked actively for 3 nights on old phone batteries without recharging. Perhaps it would have been enough for more, I didn’t test it before the cutoff. Lithium batteries do not like to be completely discharged. Overall, very pleased at the cost of 140 rubles. The only thing is that it is very bright, which is not always necessary. I was pleased with the presence of charge indicators on the board. When charging via USB, it glows red when the battery is charged blue.

Almost any flashlight can be converted in this way, the only question is the size of the battery. For example, iPhone batteries are not very practical, and if you tear off the contacts from the connection board carelessly, they will not be soldered.

Do not use lithium batteries if they are swollen, it is unsafe!

It happens that the protection on the board is triggered, and you need to revive it, in this case, apply voltage from the power supply or power bank. If the phone batteries are very old, then the protection of the headlamp will naturally work faster and it will go out. Although batteries from an old Nokia (more than 4 years old) work properly.

Save money when purchasing and, accordingly, buy cheaper (this is when % from the purchase accumulates). So you just install a browser extension and the money gradually accumulates on its own.

Useful video collection on modifying flashlights

Headlamp with 18650 battery In the previous article we looked at a very good modern chip - a lithium battery charge controller, now it's time to apply this circuit to
Headlamp with 18650 battery

Headlamp with 18650 battery

In the previous article we looked at a very good modern chip - a lithium battery charge controller, now it's time to put this circuit into action by upgrading several flashlights. Next, see a couple of applications of memory boards with TP4056 in flashlights:

Batteries taken from old ones cell phones, found with identical capacities, balanced and soldered into a block. In the first option, 1.5 A, in the second, 1 A. They charge quickly - approximately 1-3 hours, depending on the current used.

Next, I started converting another old camping flashlight for a 18650 lithium battery, I drew a signet for it, it came out almost like the original, but smaller. I tried charging, it works. I'll collect the whole lantern.

But I finished another old camping lantern. It is possible to change lenses for different focusing of the light flux. I replaced the acid battery with a 18650 type battery and added a charger on the same TP4056, the capacity of the used battery is 1.3 A:

Another case. They gave me a good case from an ancient incandescent flashlight, rechargeable from the mains.

The gel battery built into it was hopelessly dead for a long time. After some thought, it was decided to build into it a block of parallel lithium batteries, 4 pieces of 800 mA each, and expand the functionality by integrating two LEDs into the housing for 60 mA and 150 mA.

In place of the removed retractable plug, an additional aluminum plate-radiator was cut out and an SMD LED with an operating current of 150 mA was screwed on. And in place of the former light bulb, an 8 mm round LED rated at 60 mA was installed.

There was a lot left inside free space, accordingly, a ready-made memory was built into the flashlight, again based on TR4056. The LEDs on the charger board fit perfectly into the hole of the former power LED. For these charge indication LEDs, a conical indicator was machined from plexiglass and glued into the case. The result is a compact and resource-intensive (3.2 A) pocket flashlight with recharging from 5 V.

Protective plexiglass was also added to the body to protect the LED from dust. And this is a disassembled body, for a clearer visual acquaintance with the contents of the converted flashlight. There is still empty space left; it is quite possible to add a boost converter for recharging a cell phone.

In this way, old electronic structures and devices can be given the opportunity to continue to serve, using modern electronic database in a new technical quality. And all this can be done with a small, cheap 4056 microcircuit. I was with you Igoran.

Headlamp with 18650 battery

Many people are familiar with lanterns, ttype "Era" or "Cosmos" FA21M, as well as their numerous clones under other names. WITH30 watt halogen lamp and 6 volt/4.5 ampere hour lead gel battery. They are still sold now, just like many years ago - except that the lamp has been replaced by an LED panel...

Actually, in lead battery and high power lies the problem with such flashlights. Their power is categorically excessive for a home/garage/car, etc. – unless in a field or on the water such a spotlight makes sense. The dimensions are also excessive - it’s unclear where to put/put this dinosaur...
As a result, everyone who bought such a flashlight or received it as a gift (they liked to give them on February 23, hehe...) sooner or later put them aside, and when, on occasion, they took them out, they discovered that the battery was hopelessly degraded - the flashlight charges quickly , lights up after that for a couple of minutes, and goes out...

The cost of a new battery is completely unreasonable, it often exceeds the cost of the assembled flashlight, so such flashlights are often sent to scrap.However, the huge body gives DIYers room for creativity. You can put an LED lamp there, you can fill it with lithium batteries so that it burns continuously for six months, you can insert a PWM controller and much more.
True, the lantern will still remain hefty and awkward...

I picked up such a flashlight at a dacha dump, complete set in a box - someone apparently had it lying around at their dacha until the battery completely degraded, and after finding out the price for a new one, it was thrown into the trash. And I decided to make a compact flashlight out of it to illuminate the route when swimming on a boat at night. The peculiarity of the modification is the use of a native halogen lamp - firstly, it is already there, which means it is free, and secondly, it shines really powerfully. Converting this flashlight to an LED is not very advisable - the geometry of the reflector, designed for an incandescent lamp, is not very suitable for a diode...

We unscrew the extra bulky plastic from the flashlight - the black “crown” around the reflector, the handle, throw out the battery, remove the switch, and then use a hacksaw blade to cut off the “head” - this is exactly what we need:

Here's what happens:

We cut out a cover for the head from any plastic and place it on 5 M2 screws with nuts.

Oddly enough, holding this freak in your hand is quite comfortable. I only made a rope lanyard so that the lantern would hang on it if it slipped out of my hand.
But fantasies will - you can even attach a three-kopeck door handle, even screw in a bolt and, if necessary, screw an empty tube onto it with a pressed-in nut, which acts as a classic lantern handle - whatever you like. You can even add an elastic band and make an extremely powerful forehead protector...

Review of 18650 batteries for different devices, converting the battery for a screwdriver, the best batteries from AliExpress

TEST:

To see if you have enough information about your lithium-ion battery:

1. When purchasing 18650 batteries for a security flashlight, which manufacturer is preferable?

1. What indicators should chargers for 18650 provide?

a) The output is 5 Volts and the current is from 0.5 to 1 from the nominal capacity of the battery itself.
b) The output is 10 Volts and the current is from 1 to 3 of the nominal capacity of the battery itself.

1. In what temperature range is it desirable to store the battery?

a) + 10 – + 25 – ideal indicators. The battery does not tolerate extremely cold or hot rooms. b) At a temperature of +20 - +45 degrees.

1. How many stages does a lithium battery take to charge?

a) Two.
b) Four.

1. How many charging stages does a lithium battery have that charges in less than an hour?

Answers:

1. b) It is advisable to take Chinese KEEPPOWER batteries. Samsung does not produce models with protection.
2. a) The correct output indicators are 5 Volts and the current is from 0.5 to 1 of the nominal capacity of the battery itself.
3. a) + 10 – + 25 – ideal indicators. Do not place the battery in other conditions.
4. a) Two stages - first with a voltage of 0.2-1A, and then with a high constant.
5. a) Only one. The element is immediately supplied high voltage. The remaining stages are missing.

Nickel-cadmium problem battery, installed in the screwdriver, is that it must be used constantly. If the battery is completely discharged or is not used for a long time, the crystallization process will begin in it, and the battery will soon fail completely.

To replace battery you will have to spend a lot of money, since batteries suitable for a screwdriver are not cheap.

For these reasons, screwdriver owners modify the battery slightly to accommodate lithium cells. But before the start similar works you need to think about whether such a modification is necessary and whether it is advisable at all.

Definition: Battery The 18650 is a battery that produces 3.7V power.

3 pros and 5 cons of conversion for a screwdriver

Advantages of remodeling:

1. The energy density of the elements will be better than nickel-cadmium. It means that screwdriver will retain its original weight, even be somewhat lighter, while the output voltage will remain within normal limits.
2. Lithium batteries Charge much faster than others. It only takes one hour to charge them safely.
3. In lithium-ion batteries no memory effect. From this we can conclude that there is no need to completely discharge them before installing them on the charger.

Flaws:

1. If you install lithium battery, you will have to carefully monitor it: when charging, it cannot be charged above 4.2 Volts, and discharged by less than 2.7 Volts. Otherwise, the battery will simply fail.
2. 18650 cans are used as lithium cells. They are different in size from nickel-cadmium ones. In addition, you will have to find a place for the charge-discharge controller of the wires. And all this should somehow fit into the body of the screwdriver.
3. Chargers for cadmium batteries may not be suitable for conversion. You may have to additionally look for a universal charger.
4. It will not be possible to work outside in winter, since lithium battery Does not tolerate negative temperatures well.
5. Lithium-ion battery costs more than cadmium.

It is also important to know 3 nuances before starting work

1. First you need to decide on the number of elements in battery. It is best to use 4 elements, since three will only give 12.6 Volts.
2. Assembling the battery 18650, It is necessary to pay attention to the capacity and discharge current. When the battery is running, the current consumed is in the range of 5 or 10 amperes, but if you sharply press the power button, it can jump to 25. This suggests that the maximum discharge current value should be approximately 30 amperes on the battery 18650.
3. You should also pay attention to the controller. Its characteristics must be equal to the rated voltage and current discharge. For a 14.4 V battery, the controller is the optimal voltage. The operating current should be several times less than the maximum permissible.

How to avoid 4 mistakes when assembling a 18650 charger

To properly connect to battery lithium cells, you will need to follow the instructions exactly:

Chargers for 18650 batteries

For battery 18650 will have to be used correct charging. At the output it will produce 5 Volts and a current from 0.5 to 1 of the rated capacity of the battery itself. If lithium cells support 2600 mAh, then a current of 1.3-2.6 amperes should be used to charge it.

Device for lithium batteries The battery is charged in several stages:

1. First on battery a voltage of 0.2-1A is supplied.
2. Further charger already takes place at constant voltage.

If the charger has pulse mode, this will significantly speed up the charging time.

In the event that the battery has graphite, then the voltage should not exceed 4.3 Volts per element. If you exceed this figure, the energy density will increase and the oxidation process will begin.

There are lithium batteries, charging in less than an hour. They do not provide for the second stage - the current is immediately supplied to 80% and after that it is put into operation. This is normal for a lithium battery.

Answers to 5 frequently asked questions about choosing an e-cigarette battery

Battery

Look at the picture battery 18650 for an electronic cigarette. It is quite difficult to choose the right battery for an electronic cigarette, since there are many varieties with different degrees of power. Eg, long-term workers but they cannot be turned on at full power. Others won't get hot even at 40 amps, but they require frequent charging. When selecting a battery for an electric cigarette, people wonder about the criteria.

There are five main criteria: Large energy intensity, rated current indicator, voltage when used, temperature when used, cost. There is no point in paying attention to other nuances, like the color of a cigarette. All this is secondary. To choose a good unit, you should study all the criteria in detail. As a result, the buyer will receive all the necessary information for a good purchase.

Energy intensity

Electronic Cigarette

Energy intensity expressed in milliamps per hour. Accordingly, the higher this indicator, the better the model will be. Safety depends on the rated current. The conclusion suggests itself that it is advisable to buy batteries with the highest current supply. For example, the LG hb6 battery has 30 A, which means it is suitable for 40 A. But having made such a purchase, a person will prefer high voltage and sacrifice energy intensity. The energy capacity of the above battery is only 1500 mAh. Therefore, it will hold less charge than options with 3000 mAh.

It is necessary to select indicators rated current, which will not overheat the device, but do not sacrifice battery life. It is better to purchase the LG HD2 model, which has a rating of 25 A and microamps per hour. This will be the average. As for the voltage, you should not rely on this nuance when choosing - if the cigarette has two previous indicators that are good, then the voltage will be sufficient.

Which battery is better for a led flashlight? flashlight charging tests.

You also need to choose devices, having a low degree of heating. Overheating an electric cigarette will soon damage the entire mechanism. That is why you need to take a battery that will work at the lowest temperatures. Price cigarettes approximately the same and this is not the most important criterion. It is advisable to start from the indicators first.

Top 3 best battery chargers

Nightcore digicharger D4

Charger device Can power four batteries. This is an already proven brand, loved by many owners of lithium batteries.

Device It is equipped with a convenient display - you can study various data, including charging speed and time, voltage on each element. It is very convenient to monitor the battery status on this display.

This is universal charger, is not only for the 18650 model. D4 should be used by people who have a large number of mobile devices, which accommodate several types of rechargeable batteries.

Beginners will quickly master the work, since charging occurs automatically mode.

Efest luc Blu6 oled Bluetooth intelligent Charger

It's also very good model charger devices, designed for 6 batteries. To safely charge, the device is equipped with special protection against high current, voltage, and so on.

The user gets the opportunity to connect his mobile phone with charging via Bluetooth- You can remotely monitor the battery charge level. The only drawback of charging is the high price.

Nightcore i2 intellicharger

Charger went on sale recently. This is a modern type of device, equipped with interesting features and improved design.

Users don't need to worry about speed and time charging, because the device detects everything in automatic mode. The person only needs to install the battery in its proper place.

The device only has room for two batteries, but the charger is very compact and can be taken with you when traveling.

Li-ion battery 18650 for flashlight

1. Lithium-ion batteries operate in the range of 4.35 - 4.2 Volts. They are often used to make LED lights work.
2. You need to make sure that battery did not discharge below the set level - 2 volts. In order not to constantly monitor the required voltage, you need to use battery for flashlight with protection. They store elements from overcharging or deep vacuum.

Companies Samsung, Panasonic, LG and Sony do not produce such equipment. For this purpose, it is better to purchase a Chinese KEEPPOWER device.

The best 18650 batteries on AliExpress according to reviews

1. Rechargeable Battery
2. Samsung icr18650
3. Rechargeable flat Top Battery

Ideal conditions for batteries– temperature +10 – +25 degrees.

The new flashlight... sat for a year and its battery died (as it turned out, this happens with similar flashlights, the same thing happened to 4 friends) - it’s a shame to throw it away (used it once), a new battery is very difficult to find + cost of the battery = cost of the flashlight... found a simple solution to the problem…
It is interesting that the lanterns had different operating conditions (by February 23 they were presented to employees) - but everyone died “in one hour.” Naturally it’s a shame, I just needed it, the “new” one is on you too :)))


Having tried to look for similar batteries in special stores and markets, I came to the conclusion that it is completely inappropriate to buy such a battery for the cost of a flashlight. I couldn’t find a cheap alternative, and besides, the battery characteristics were confusing... That is. 5V was strained when converting to a different type of battery...


But there was no desire to radically redo the charger and flashlight.
At first there was an idea to plug in 18650 - but the voltage is a volt lower (how the flashlight will light - again alterations... + disassemble/assemble for charging... in short, problems again :(

The solution was found to be very simple - buy an external cheap power bank, which already produces 5V output and has a built-in charging system CHEAP AND TASTY :)

In fact, the original battery had 2Ah. It is clear that in our case there are all kinds of unnecessary losses - but the price justifies the means + some advantages appear :)

Literally on my knees, the flashlight was disassembled, the network connector was removed (the charge was from 220 in the original) and, well, the “interfering wires” - it was actually possible not to touch them :)
Instead of the original battery, I used a power bank with a 2600 can, removed the original cover from the power bank, and secured it with electrical tape so that the structure would not fall apart due to vibrations or shocks.
In fact, everything can be done MUCH more accurately naturally, but I was interested in the simplicity and speed of the solution.





This is roughly how it turned out (the wiring did not have to be pulled out through the power bank, at first there was an idea for a slightly different arrangement).
Those. I secured the power bank itself by inserting it into the former network connector, even without additional ones. the mount sits quite firmly

Main advantages:
The lantern is alive!
Quite easy and inexpensive!
It is easy to change the battery (in case of failure) - they are common and inexpensive.
You can charge from any USB (including in a car), and also, if necessary, use it as a power bank (depending on the quality of the latter).

The flashlight shines normally. I didn’t try to time it, but it shines for a VERY long time, probably for several hours, I didn’t try to discharge it at once.

I'm planning to buy +23 Add to favorites I liked the review +38 +71