DS2: Retrofit torch // University of Oldenburg

Introduction

In this lesson, the students follow step-by-step instructions to convert an old torch by replacing the old/defective bulb with an LED. Due to the large number of models, the assembly instructions can only show the essential steps. The pupils are required to carry out the missing steps on their own responsibility and according to their torches.

Preparations

The students bring their own torches for this lesson. A series resistor for the LED is required for torches with more than two AA batteries. The assembly instructions must be provided in sufficient quantities.

Material overview

* LED
* Cable strand
* Batteries
* (Resistors)
* Flashlights
* LED socket
* Hot glue

Documents

Instructions

Step 1: Inspect the torch. Take a close look at the torch and check the functions of the components.

Step 2: Dismantle the torch. Put everything down so that it cannot get lost.

Step 3: Take a look at where the positive and negative poles of the lamp are. This step is important in order to solder the G4 socket correctly later.

Step 4: Find out which lead of the torch is connected to the negative terminal of the batteries and which lead is connected to the positive terminal of the batteries. Tip: To find out where the positive pole and the negative pole are, look at the batteries.

Step 5: Remove the bulb. Test whether and how the new base fits into the torch. Measure how long the wire needs to be.

Step 6: Shorten the stranded wire and remove a suitable piece of insulation.

Step 7: Twist the strands together and then tin them with solder.

Step 8: Solder the blue wire to the contact for the negative pole and the brown wire to the contact for the positive pole. Ensure that the bulb holder functions properly so that it can still be fitted.

Step 9: Cut the LED connections to 8mm to 10mm using the side cutters. Then insert the LED into the socket. Make sure the polarity is correct.

Step 10: Test the torch. To do this, fit the lamp holder with the LED and assemble the torch.

Step 11: If the torch works, take it apart again and fix the G4 base in the socket with hot glue. Make sure that the base sits straight in the socket or reflector. Caution: Risk of burns from the hot glue!

Step 12: Test the torch again.

Tool list

* Soldering iron
* Side cutters
* Clamping tweezers
* Hot glue gun

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DS2: Retrofit torch