Converting A Chinese Headlamp Into A Rechargeable One With Usbi Charging

2023 Author: Philip Bishop | [email protected]. Last modified: 2023-05-24 22:24

Board parameters
Let's start rework
Useful video collection on the finalization of the lanterns

The idea of how to convert a headlamp into a rechargeable one arose a long time ago, especially when fishing and when installing electrical wiring. Since it is unprofitable to constantly buy batteries, in our age of mobile phones. After thinking it over and ordering the necessary spare parts, which I will describe below, I proceeded to modify the headlamp for batteries with my own hands, using the Chinese charging circuit, which makes it possible to charge the battery both in the car and from a conventional micro USB of a modern phone. I usually order on Aliexpress, although it is possible to find it in stores, but it is 2 times more expensive.

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

The idea is very simple and everyone can do it, you only need a small battery from an old cell phone, there is a Li-Ion battery with protection. It fits perfectly in terms of voltage, the LED flashlight has a voltage range of 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 one more battery in parallel. It is only necessary to correctly identify the contacts (most of them indicate plus and minus), it remains to carefully solder the contacts so as not to melt and avoid short circuits.

The problem with charging through an ordinary micro usbi is solved simply, order a small board costing about 20 rubles. Micro USB plays a very important role in controlling the charging and shutdown of the ice lamp when the battery is discharged.

The board has LED indicators that indicate in color when the converted LED flashlight is charged. Thus, the revision 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 gives out.

It is possible to order such a scheme here for myself, I ordered 10 pieces at once, since it is universal and can be used in children's toys.

Board parameters

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

Let's start rework

Now, about the alteration of the flashlight for a battery instead of batteries, most flashlights use 3 AA 1.5V in size, comparable to a mobile battery, and fits well in the main body, only you have to expand the seat. After simple manipulations, having twisted or cut out all unnecessary, we mount all the parts in places on hot melt glue.

In conclusion: the LED flashlight worked actively for 3 nights on old telephone batteries without recharging. Perhaps it would have been enough for more, I did not experience it before the cutoff. Lithium batteries don't like being completely discharged. In general, I am very satisfied with the cost price of 140 rubles. the only thing is that it is very bright, which is not always needed. I was pleased with the presence of charge indicators on the board. When charging via usb, it glows red when the battery is charged in blue.

In this way, you can remake almost any flashlight, the only question is the size of the battery. For example, the batteries from the iPhone are not very practical, and if you tear off the contacts from the connection board inaccurately, they will not be soldered yet.

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

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

To save money when buying and, accordingly, to buy cheaper, it is quite possible to use cashback (this is when% from the purchase accumulates). So just install the browser extension and money will gradually accumulate on its own.