LED Track Lights

Pigs in the Kitchen

I created LED track lights for a doll house but they can be mounted anywhere, like the bookshelf under the dollhouse.

All lit up! First picture.
The shelf under the dollhouse makes a nice park.

Proof of Concept

I had this simple idea that I could run a bare copper wire though a print for power. I discovered making a solid connection to the wire is not easy. After trying a few different approaches I came up with the slot-cap.

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Wide slot for easy access
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Slot-cap secures and clamps
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Assembly required

The slot-cap secured the connection by combining a large area for contact and a clamping action to keep the connection tight. I installed 84 LEDs in this dollhouse without a flicker.

Parts

Power requirement

I used 84 LEDs and based on 15ma per LED that is 84*15ma = 1.26A. That means I need at least a 1.25A 12VDC power adapter.

Photography

The lights really bring the scenes to life which can be easily captured with a cell phone. A modern way to play with a doll house; create scenes, take photographs and put it all together in a story.

FreeCAD

The tracks were created using FreeCAD and a custom Macro I wrote. I haven’t done a writeup on this design but have a post on using FreeCAD with Macros for information.  

Print

NOTE: Wire channels in tracks
Printed guides with slot-caps
Ready to Thread, slot-caps in place

 

Assembly

  1. Using pliers with small movements push the bare wire into the channel until it comes out the far end. Put the clamps in place so the wire will follow the guide they create.  If a wire sticks open caps to see if it is catching on the entry point. 
Carefully push small amounts of wire in by clamping pliers close to the entrance and pushing. To avoid bending push small amounts at a time.
One channel wired
  1. Clip wire and thread second channel
Both channels wired
Tracks wired and setup for LEDs
The LEDS should all have their long lead (+) on the same side. I use ‘left’ based the LEDs being face down with the tail on the back side.
LED flush, ready for lead bending
Bend leads across and down into the slot
Crimp leads with pliers as close as possible to the bare wire
LED leads are bent around the bare wire with their tails in the slots
Slot-cap is pressed into place. Use pliers carefully if necessary to close the gap
Clip LED leads flush with Light track.
Clipped LED leads. If you are concerned with shorting clip the leads before pressing in the caps so they cannot be easily reached.
Tracks with wire threaded.

Plug it in

Connection is simply positive to the positive side, and negative to the negative side.

I wrap and solder 22 AWG Solid hookup wire to the solid copper tails and clip the tails just above wrap.

Clip Solid Tails 1
Clip solid tails
Clip Solid tails 2
Ready for heat-shrink

Slide the heat-shrink to the Track Light and shrink.

Connection tail
Ready for install
Light Track Screws
Light Track Screws 2x10mm
LED Track Lights and Power Track
LED Track Lights

Next

An alternative to connecting wires with connectors or solder in the next post I will present the Power Track.

Author: Marc

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