2 in 1 DIY Electronics Device making

INDRODUCTION:

When working with electronics, having the right tools is essential. Whether you’re testing LEDs or checking circuit continuity, this DIY 2-in-1 LED Tester and Continuity Tester is a compact and useful tool for any electronics enthusiast.

This project combines two functions into a single device:

1. LED Tester Mode – Allows you to quickly test LEDs and check their brightness and polarity.

2. Continuity Tester Mode – Helps verify electrical connections and detect open or short circuits with an audible buzzer.

The device is built using an XL6009 boost converter to provide an adjustable voltage, a toggle switch to switch between modes, and banana sockets for easy probe connections. It is housed in a repurposed charger enclosure with an acrylic panel, making it a portable and durable tool.

Step 1: Preparing the Acrylic Sheet

In the first image, a transparent acrylic sheet is being held by both hands. The sheet is clean and clear, with small blue markings that indicate where holes will be drilled. This step involves:

• Selecting and cutting the acrylic sheet to the required size.

• Marking precise drilling points using a marker for proper alignment.

Step 2: Drilling Guide Holes

In the second image, a rotary tool (such as a Dremel) is being used to drill holes into the acrylic sheet. The pre-marked points are used as a guide. This step involves:

• Securing the acrylic sheet to prevent movement.

• Carefully drilling small pilot holes before enlarging them.

• Ensuring smooth and clean drilling to prevent cracks.

1. Preparing the Panel:

• The acrylic panel has pre-drilled holes for the banana sockets.

• Two banana sockets, one red (positive) and one black (negative), are being used.

2. Inserting the Banana Sockets:

• The plastic insulating parts of the banana sockets (red and black) are being placed into the corresponding holes in the acrylic panel.

• A pair of tweezers is being used to position the black insulating ring into its hole, ensuring a secure fit.

3. Alignment Check:

• Before securing them with nuts, the sockets are positioned correctly in the panel.

A 9V buzzer is being used as the sound indicator for continuity testing.

In LED testing mode, the switch connects the circuit in such a way that a controlled voltage and current are supplied to the LED under test. The 2.2KΩ resistor limits the current to a safe level, preventing damage to the LED. When an LED is placed between the test terminals, it will light up if it is functioning properly. This setup ensures that LEDs of different colors and voltage ratings can be tested safely.

and connect toggle switch one side to -ve terminal of buzzer

• The XL6019 module regulates the voltage and provides a stable output voltage.

• The positive output from the module is connected to the center leg of the toggle switch.

• A toggle switch usually has three terminals:

• Center leg (common terminal) – This is the input, which receives power from the XL6019 module.

• Left terminal – Connects to one output (e.g., continuity tester).

• Right terminal – Connects to another output (e.g., LED tester).

The XL6019 module is a DC-DC boost/buck converter that can increase or decrease the input voltage based on the circuit requirements. It is a high-efficiency switching regulator capable of handling up to 5A current and operating in a wide input voltage range of 5V to 40V while providing an adjustable output voltage.

You have used a mini 3-wire voltmeter to display the voltage in your circuit. Below is a detailed explanation of how you have connected it:

Connections of the Mini 3-Wire Voltmeter:

1. Red Wire (Power Input):

• Connected to the input of the XL6009 module.

• This provides power to the voltmeter so it can function.

2. Black Wire (Ground):

• Connected to the GND of the XL6009 module.

• This completes the power circuit for the voltmeter.

3. Yellow Wire (Voltage Sense):

• Connected to the positive banana socket.

• This allows the voltmeter to measure and display the voltage at the banana socket.

• You took an old charger casing, likely because it provides a compact and enclosed housing for your components.

• The enclosure helps keep the circuit protected from dust and damage while making it a portable tool.

To power your XL6019 DC-DC boost converter, you are using a Type-C socket as the input power source. Here’s how you can properly solder and connect it:

1. Identify the Type-C Socket Pins

A standard USB Type-C socket has multiple pins, but for powering the XL6019, you primarily need:

• VCC (5V or higher depending on source) → Power Input

• GND (Ground) → Common Ground

To achieve a clean and polished finish on an acrylic sheet, you are using a file to smooth all four sides. Here’s how to do it properly:

1. Choose the Right File

• Use a flat file for straight edges.

• A fine-toothed file is recommended to avoid chipping or cracking the acrylic.

2. Secure the Acrylic Sheet

• Place the acrylic on a stable surface.

• Use clamps if needed to hold it securely while filing.

3. Filing the Edges

• Hold the file at a slight angle to the edge.

• Apply light and even pressure, moving the file in one direction (not back and forth) to prevent roughness.

• Repeat this process along all four sides of the acrylic sheet.

4. Finishing Touch

• After filing, use sandpaper (400-600 grit) for a smoother finish.

• Wipe the edges with a clean cloth to remove dust.

The potentiometer (blue component with a small screw) controls the output voltage.

• It is usually a multi-turn type, meaning you need to rotate it several times for fine adjustments.

. Adjust the Output Voltage to 29V

• Use a small screwdriver to turn the potentiometerclockwise to increase voltage.

• Turn it counterclockwise to decrease voltage.

• While turning, observe the voltmeter reading.

After setting the toggle switch to the right side, the device switches to LED tester mode. In this mode, the output voltage is regulated, allowing you to test all types of LEDs, including standard, high-power, and SMD LEDs.

After setting the toggle switch to the left side, the device operates in LED tester mode, allowing you to safely test LEDs using the preset voltage and current-limiting resistor. When the switch is flipped to the right side, the tool functions as a continuity tester, helping to check for electrical connections in circuits. In continuity mode, when a complete circuit is detected, the buzzer sounds, confirming a closed path. This 2-in-1 feature makes the tool versatile, enabling both LED testing and continuity checking with a single compact device.

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