SMART LED FLASHLIGHT - a Tiny Personal Emergency Light Sensing LED Flashlight, Made From Available Components and Very Simple for Replicate Itself in 20 Minutes.

How it works:

The flashlight turns on automatic for 60 seconds when it senses that the room is dark enough.

To turn on manual light for additional 60 seconds you need to push the RST button.

The Light sensing LED Flashlight is invaluable for emergencies such as power failures or blackouts.

Step 1: The Flashlight Is Invaluable for Emergencies Such As Power Failures or Blackouts.

I have assembly several Flashlight, and have several dozen spear PCB board and components that I can share with any one who wish to make the flashlight.

The instructable contains:

Flashlight schematic,
PCB Assembly drawing,
BOM - Components KIT cost less than $5
Tools list
Detailed step-by- step assembling instructions.

Specifications:

Number of flashlight components: 15
Color of LED’s light: white
Number of LEDs: 3
Light Distance: 2-3 meters
Size of flashlight : 26.25mm x 20mm x 5mm
Current consumption :
LEDs turn ON: 4-5mA
LEDs turn OFF: 30-45uA
Battery capacity: 140mAh
Battery voltage: 3V
Battery life : up to 6 months (if flashlight turns on 2 times for 60 sec in 24 hours)
Required skills : knowledge of soldering SMD components

Step 2: Light Sensing LED Flashlight Schematics

The Light sensing LED Flashlight Schematics contains the next blocks:

3 White LEDs (LED1 - LED3) and 3 current limit resistors (R1 - R3)
16 bit ultra low power micro-controller of firm Texas Instruments (U1)
Power on (R4 and C1) and manual Reset (S1 push-button) micro-controller circuit
Light sensor (PH1) and resistor R5 - is voltage divider circuit
Flashlight battery 3V, 140mAh

Step 3: The Light Sensing LED Flashlight PCB

I ordered the PCB from a Chinese low cost prototype PCB manufacturer.

The PCB Specification are:

Dimensions: 20mm x 26,25mm
Layers number :2 Layers
PCB Type: Normal FR-4 Board
FR4-TG: TG 130-140
Thickness: 1.6mm
Solder Mask: White
Silkscreen: Black
Surface Finish: HASL with lead
Finished Copper: 1 oz Cu

Step 4: The Light Sensing LED Flashlight BOM

All components for assembly Light sensing LED Flashlight I put in a plastic box.

I ordered wholesale quantity of all components.
For myself, I made 4 flashlights and the rest of my Flashlight components put in plastic boxes and share in https://www.tindie.com/products/WihiteRobot/light...

There you will be able to get them at a price lower compared to cost of components purchased for a single flashlight. So if anybody will want build the flashlight I advice first check if remained a spare kits in https://www.tindie.com/products/WihiteRobot/light...

The FLASHLIGHT KIT include all flashlight BOM components (+ 5 spare small SMD) and already programmed micro controller.

Step 5: Tools

Simple Digital Multi-meter Tester: that can measure Voltage, Current, Resistance, Test a Diode (optional) - use for debugging.
FLUX Cleaner. Applications: PCBs Cleaner - use for remove flax from PCB after soldering components.Liquid
Solder Flux - use removing oxide buildup. Helps spread out solder by reducing surface tension.
Flashlight Components Kit.
Tin Lead Rosin Core Flux Solder, Diameter : 0.6mm, Material : 60% Sn (Tin) & 40% Pb (Lead) -use to solder electronic components.
Wire Sponge Soldering Iron Tip Cleaning, - use for cleaning iron tip.
Desoldering Braid Solder Remover Wick Cable Wire 2.0mm 0.75m - use solder wick to remove the excess solder.
ESD-Safe PCB Cleaning Brush.
Simple Soldering Iron 30W-40W, or adjustable temperature soldering iron 60W-90W with the soldering tip suitable for SMD soldering. Soldering iron stand base with sponge.
Diagonal Wire Cutter - use for cut off the pins of through-hole components.
Stainless Steel Tweezers - use for hold the SMD components.