WLED Iron Man light, worklog

[Tolo1996]

Iron Man Led Driver
To complement the costume I am designing, WLED costume Driver, worklog - #15 by Tolo1996

I would like to add gloves with the Iron Men effect

Assumptions
The project aims to make a system based on ESP32 and WLED software, which will control two RGBW power LEDs placed on the operator’s hands.
Parameters:
-Dimensions about 100x50x30mm
-Operating time 10-20 min
-USB c charging
-Battery charge indicator
-Low current at rest (long storage)
-Housing in the style of extruded aluminum housings. (no need to place holes in the PCB)
-Design made in Easy EDA and FreeCaD

• Possibility of mounting the lens on the diode

-Use as many elements as possible from the old design

Previous project.

I have already made a similar device using the FTChip module from pyrroterra.
The project uses IP5306 chip for battery charging, MT3608 as a 12V boost converter for FT Chip power, TPS61088 chip for LED power. The CN5501 systems are responsible for controlling individual channels. XB4908A is the protection of the Two 18650 batteries that power the device. Due to the fact that the FT chip outputs are open Drain, I needed to add another SN74HCT14DR to reverse the PWM signal. The output of the IP5306 Flashlight is used to turn on the whole device. The diagram can be seen in the image below

The PCB can be seen in the figures below.

Disadvantages of the previous solution

I made a few mistakes on the board.

1. First, I used a use full connnect with the ground layer. This made the circuit very difficult to solder.
2. The electrolytic capacitors were placed in the wrong place. I was hoping to find something with a diameter of 6mm and a large capacity, but in the end I mounted them on the other side as in the photo.
3. I did not connect the exposed pads correctly.
4. The C50 is in a strange place
5. No TVS on the LED power supply (due to difficult TVS (solid connect to ground) soldering, I resigned from installing them.
6. I didn’t add battery markings on silk and the markings on the battery basket are misleading
7. No need for angled LEDs as charge indicators, ordinary LEDs shine sufficiently to the Sides
8. TPS to LED converter is probably redundant, but I’ll have to check it
   On the other hand, I could power 12V LED strips, to check

Case

The enclosure was made as a 3D print. The PCB is inserted and secured with two panels on the front and back

Mistakes made with the enclosure

1. Too low a height of the cell expands the housing.
2. Buttons should not protrude beyond the outline of the case
3. Inscriptions on printouts are illegible
4. The screws in the middle of the panel are missing or the enclosure is too short and the PCB pushes the panels sideways.

Led

In the previous solution, the LED was attached to the operator’s hand by a neodymium magnet. A piece of metal was sewn into the glove to which a magnet attached.
The wires were brought directly to the diode’s heatsink, the whole was secured with heat-shrink tubes.

The disadvantages of this solution are.

1. It is very difficult to solder cables to LED. Outside of this cable, they can fall off or break.
2. The magnet may lose its properties under the influence of temperature and fall off the glove
3. The magnet holds poorly and can twist.
   Pictures of the solution below

[Tolo1996]

The first step I would like to take is to design a new LED holder.

The first idea looks like in the pictures. The green element is the OSTCXBEAC1E type lens holder. I would like to be able to use RGB and RGBW LEDs. The connector will allow you to easily disconnect the cable. Longitudinal slots will allow you to insert the Velcro tape. Additionally, as an option, I placed a number of holes on the edge that can be used to sew the PCB to the Glove.

The second idea is to make a PCB as small as possible and make a 3D printed handle, which would give me more opportunity to experiment with different assembly methods.