Working safely is crucial. Another thing that bothers me is the waste of natural resources. This is a simple design that gathers stuff that would otherwise go to waste.
Faced with these two needs: security and reuse. This idea came about to reuse these materials and develop a luminaire for use on a bench drill
Step 1: Material
- Head lantern: 5,0V;
- Cellular charger:in 220V|AC; out 5,0V|CC;500-800mA;
- Pilot Light - https://pt.aliexpress.com/item/FREE-SHIPPING-5pcs-Pilot-Lamp-AD16-16C-DC-24V-LED-Power-Indicator-light-16mm-Signal-Lamp/32770459707.html?traffic_analysisId=recommend_3035_null_null_null&scm=1007.13338.80878.000000000000000&pvid=acfe8eb7-860e-4181-92c2-a5e3d2dfcd8a&tpp=1
- Three-pin switch with pilot light (optional); - https://pt.aliexpress.com/item/4pcs-On-Off-Red-Green-Blue-Black-LED-Lighted-Round-Rocker-Switch-Car-Dash-Dashboard-BoatTruck/32693929094.html?spm=a2g0s.89374220.127.116.11MDNUT
- Flexible goose neck used in table lamp;
- Yarn (preferably colored);
- Pieces of wire.
Step 2: Identifying the Parts
To start, dismantle the head flashlight;
Identify the positive and negative poles;
The charger must be functioning perfectly.
Identify the positive and negative wires.
LED flashlight test is working. Plug the charger into the mains and attach the positive wires of the charger with flashlight positive and negative with negative. If it turns on, let's go to the next step
Step 3: Overview Schema
I also took advantage of the opportunity and added a pilot light, which will indicate when the drill plug is plugged into the power grid.
Look at the general schematics.
Let's see how the circuit will work.
When the plug is connected to the mains, the led (pilot light) lights indicating current and the light can already be turned on, even without the drilling machine running. To do this, just turn on the light switch. The drive is independent of the light and drill.
Step 4: Drilling Holes
Before making electrical connections we have to make the holes where the pilot light will be set and the switch for the lamp. Choose the best position and make the appropriate holes. I chose the front side with the lamp switch to the left and the pilot light on the right
Both the pilot light and the switch I used is 16 mm diameter. I made a hole with 10 mm drill and widen with micro grind until reaching the 16 mm
Step 5: Let's Break It Down Into Three Parts:
1 - light connection;
2 - pilot light connection;
3 - interconnection with the drill.
Step 6: Light Connection
We'll need a three-pin switch with pilot; a cell phone charger; light and wires (preferably colored). Tools will be required for welding the wires.
1.1 - We need to make a modification to the charger.
Cut the plug that connects the charger to the mobile device. Identify the positive and negative wires. After passing through the charger the current is continuous (DC).
Open the charger and identify the two electrical input wires connected to the plug. At this point the current is alternated (AC).
With a soldering iron remove the two wires and in place solder two longer wires (20 cm). These served to connect the charger to the three-pin wrench.
1.2 - Three-pin wrench
connection I preferred the three-pin key with lighting to give the project a legal effect. Nothing prevents you from using a two-pin wrench making a simple connection.
From the two wires coming out of the cellphone, attach one wire to the middle pin and the other to the pin beside (neutral).
Solder two 20 cm wires on the outer pins this will be connected in parallel to the drill switch.
Step 7: Pilot Light Connection
This link is simple. The device is not polarized, we can connect phase or neutral on either side.
Two 20 cm wires for each terminal
Step 8: Interconnection With the Drill
Open the box where the drill switch is located and locate the incoming phase and neutral wires.
Disconnect and cut the electric current input connectors
Step 9: Join the Circuits
Let's join the circuits
In the general scheme, see diagram, in the area with a circle shows a jump between the pilot light circuits and the lamp.
Now you have 4 wires: two of the pilot light (white | green) and two of the 3-pin wrench (yellow | black). Insert them into the drill switch box. Using a screwed connector, attach the phase wire (black) of the wrench to the wire (green) of the pilot light. The other wire of the pilot light (white) joins the other wire of the switch (yellow).
On the opposite side of the screwed connector, on the side connect a blue wire (phase) and the other purple (neutral) wire.
These two wires will be connected to the drill wrench, phase blue and neutral purple.
Set the switch and pilot light in the holes.
Finished, pass the calls and make sure you did not make the wrong calls.
Before you close the test key. Plug in the mains plug the pilot light comes on and the drill, if activated, should work.
Step 10: Pinning Parts
For the attachment of the cellular charger I made two holes in the front of the cover and using a nylon clamp I fixed the charger inside the cover
To prevent any wire from twisting on the belt or pulleys I used wires attached to the existing screws and lashed the wires to it.
Fixing the lamp
On the top of the drill there is already a hole, we will use it to fix the flexible to the drill. We used washer and a nut for fixing.
Finishing the lamp installation
Once the flexible was fixed, I passed the wire coming out of the charger from the inside until it came out on the other side.
I passed the wire through the hole in the flashlight.
Step 11: Welding the Wires in the LED
The next step is to weld the wires in the LED. Caution LED's polarity. Always weld positive with positive and negative to negative. Caution Not about heating the LED, make a quick solder.
Finished welding make new test to check if the connections are good.
Caution – Do not look directly at the LED.
If everything is OK, close the flashlight.
Step 12: This Is the Final Appearance.
The focus of lamp does not disperse or obfuscate, is well concentrated on the desktop. The flexible goose-neck allows you to position the light in the desired area. It is gratifying to see materials that would be thrown out to be reused