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changing optics on DLP LightCrafter

Hi,

I'd like to replace the LEDs and lenses of the lightcrafter with custom optics based around a low-power laser.  Is it possible to remove these components without having to mechanically break anything?  I am comfortable with the optical and electrical design, but I am concerned whether there are interlocks or pieces of plastic welded in place that will make this tricky. Thanks!

Daniel

  • Hi Daniel,

    The optics of the LightCrafter can be replaced. I will upload an image of the LightCrafter with these components removed, and highlight the mechanical parts to be taken care of ASAP. Can you please mention the wavelength of the low-power laser you intend to use. Also, it would be helpful to know the end application.

    Thanks & Regards,

    Divya

  • Hi Divya,

    I plan on using a 488 nm diode laser which will reflect off the DMD and be imaged at the sample plane of an inverted fluorescence microscope for dynamic patterned illumination. How do you overcome the interlock after removing the LEDs? I assume you need to tie some pin from the MSP430 to high voltage/ground? Is there a schematic available? Thanks

    Daniel

  • Daniel,

    The light engine can be removed. Be careful, damage to the engine is not covered by warranty. Disconnecting the LED ribbon cable will power down the LED driver and the system will still work fine. We are in the process to upload the schematics and will take a few extra days.

    To remove the light engine follow this procedure:

    • remove the system board (top board) by removing the four screws in the corner posts.
       
    • remove the three screws from the top of the light engine, you will need a Phillips P00 screwdriver
       
    • remove the four screws on the bottom thermal plate holding the LED heat sinks
       
    • remove the ribbon cables from the driver board (bottom board). Just pull-up the plastic tab and pull-up the ribbon cable. Be careful, these ribbons are fragile and easy to break while pulling.
       
    • remove the two little back screws on the board holding the DMD to the light engine. This is the vertical standing board connected to the driver board


       
    • Gently pull out the light engine. The light engine lies on the support posts, so it needs to be raised a little and gently pulled. The connector of the DMD is in the socket.
       
    • Remove the DMD by removing the two P00 screws on the light Engine
    • Remove the metal plate and carefully remove the DMD. You can mount the DMD on the socket back on the board. Note the notches on the DMD for proper orientation when placing it back on the connector. The large square notch on the package is on the left, while the triangular notch is on the right.
    I have re-arranged the boards around to have the DMD without the thermal plate sticking out. 
     
    Best regards,
      Pedro

  • It might be easier for some to remove the post on the driver board before disconnecting the light engine. With the post removed, you can lift the driver board and light engine. Then disconnect the light engine from the driver board.

  • Hi Daniel,

    We are trying to do what you have done for structured illumination. How did this work out for you? What source did you use for the 488 nm light? We looked for LED's but could only find 470 nm. Thanks for any information you can provide.

    Best,

    Joel

  • Hi,

     

    I did the exact same steps described here to seperate the optics part from the rest of the body of the device. Now when I power up the device it goes through the first or maybe the second splash screen (while trying to boot) and all of a sudden before even the boot precess is complete, the device shuts iteself down completely as if it has been unplugged (I can tell it goes through the spalsh screens because I can see those images on DMD while there is abviouly no optics part for the light to go through).

    Based on what has been discussed above I was under the impression that the device should keep on working even though the ribbon cables (for LEDs and light sensor that go from the driver board to the optics part) are disconnected.

    So, can some body please help me out a little here and tell me what could be the reason that the device shuts iteself down after seperating the optics part?

     

    Regards,

    Houman

  • Hi Houman,

    The MSP430 v2.6 and above monitors the LED_ANODE voltage on the LED driver circuit and the LightCrafter goes into shutdown mode when LEDs are disconnected.

    We are working on releasing a new firmware which fixes this issue. For now, you have to connect the light engine back and downgrade the MSP430 to v2.5. The MSP430v2.5 is part of DLP LightCrafter Firmware and Software Bundle v1.1.

    Regards,

    Divya

  • Hi Divya,

    Any progress on your side with regard to the new MSP430 firmware upgrade that will address the problem with the LightCrafter going into shutdown mode when the LEDs are disconnected? Any tentative release date?

    I am facing this issue right now after the optics part was separated from my LightCrafter unit. I will, for now, revert to firmware version v2.5 to get going. But there is a price to pay when downgrading as v2.7, which I currently have on the board, brings a couple of important bug fixes. Also the latest GUI v4.0 displays a warning message when it encounters a MSP430 with a firmware version lower than v2.7

    Best regards,

    Michel

  • Hi Michel,

    The new software will be released very soon, hopefully by the end of this week. You can ignore the GUI warning about the MSP430 firmware.

    Best regards,

    Blair

  • Hi  Divya

    Currently we are interested in the LightCrafter and will buy one soon.  We are going to follow this method to replace its optics.  The laser we are going to use is 780nm,  about several watts. I want to know is there any thing to take care of, besides the firmware?  For example, is there any requirement for the laser we use?

    Best,

    Zhan

  • Zhan,

    When replacing LED with Lasers there are a few things that need to be considered:

    • Laser illumination power. The DLP3000 data sheet shows the maximum illumination power density for the DMD. See thisapp note for more information.
    • Thermal power. The DLP3000 data sheet describes the micromirror array temperature calculation and recommended operating temperature for the DMD.
    • Laser driver. The LightCrafter LED driver circuit was designed to drive an LED. Lasers had different voltages and current rating, that might not match the feedback network of the LightCrafter LED driver.
    • Diffraction Effects. Shining a laser into an array of periodically spaced micromirrors creates diffraction effects. This app note introduces these diffraction effects.
  • Hello Zhan,

    TI DLP recognized design house are already selling the customized light engine that will fit your requirements, you can take advantage of their services.

    You may want to get in touch with EKB http://ekb.co.il/pages/products.php and KeynotePhotonics http://www.keynotephotonics.com/lc3000-pro-dlp-pico-projector-with-near-ir-led-dlp-pico-projector/

    Regards,
    Sanjeev

     

  • Hi  Sanjeev

    The laser we are going to use is created for experimental research. So the laser must be created by ourselves.   From the website you gave me, I can hardly find the user-manuals or detail information.  Should I contact via the email provided there, or can you offer me some directly?

    BTW,  the reason we choose this LightCrafter  is because it offers us cheap method for fast development of the laser pattern.

     

    Best,

    Zhan

  • Hi Divya,
    Can the project lens be removed? I'd like to remove only the project lens, not the entire light engine.

    Thanks

    roy
  • Hi Roy,

    I tried my best to remove the project lens, and I was not able to.  I think someone can easily break it and damage it during the attempt.  It will also void any warranty (if applicable).

    Please see this excellent post:  A look inside the Young Optics' Light Engine in LightCrafter. since it may be helpful, but this post does not address how someone could remove the lens.

    Regards,

    A214529

    A look inside the Young Optics' Light Engine in LightCrafter