TEST & MEASUREMENT FEATURE
According to research by KPMG, the total value of products and services in the test and measurement (T&M) industry is more than $130bn. With the market driven
by increasing complexity, shorter product life cycles, tighter regulation, high efficiency and cost savings, manufacturers are packing single, multiple-use T&M devices with
features. Neil Oliver, technical marketing manager at Accutronics, considers the impact on sustainable design and handheld battery-powered test equipment
Test equipment: Considering battery life M
ost of the electrical products that you’ve touched today (from
mobile phones to toasters to cars) were made by machines that were calibrated using some form of test and measurement device. In the industrial sector, original
equipment manufacturers (OEMs) use test and measurement tools to ensure that companies manufacture products within specified tolerances over production runs that can easily exceed thousands of units. If production equipment becomes de-calibrated over time, it can result in quality control errors that can lead to finished products not being up to standard. In such environments, test and
measurement equipment serves the purpose of emulating real world conditions, enabling engineers to deliver products they know are fit for purpose.
COPING WITH INDUSTRY DEMANDS T&M devices are used in industries as diverse as telecommunications, healthcare, industrial automation, computer hardware, aerospace, defence, pharmaceuticals and automotive. To cope with the rising complexity and varying needs of these industries, T&M firms are increasingly packing their devices with added features, to the detriment of ergonomic design and battery life. For highly regulated and high value sectors such as aviation, commercial off-the-shelf T&M devices may lack the level of accuracy required. It is here that companies offer bespoke handheld pressure-calibration units, such as those manufactured by GE to simulate a flying air-pressure on a plane’s sensors while it is on the ground. These handheld pressure-calibration
units now include a complex array of internal and external pressure sensors, pumps, regulators, a backlit LCD screen, antennas for GSM and WirelessHART communication, as well as on-board processing and storage modules.
BATTERY USE The problem is that although technological innovation has allowed these devices to operate in complex applications, manufacturers still supply the units with eight AA batteries which, under normal use, will last only a day before needing replacing. Traditionally, 1.5V alkaline cells have been designed-in. These are used in devices so that the OEM doesn’t need to supply a rechargeable Lithium-ion (Li-ion) battery pack. However, while they provide a good volumetric and gravimetric energy density, they have a very poor power capability. Imagine running a small 365 production plant with only twenty devices on site – you would spend £44,000 on batteries each year and may
very low self-discharge and can handle the high current pulses seen in many test and measurement devices when they are measuring, transmitting data, or printing. A rechargeable battery is only
manufactured once and provides smart metering, so the user can accurately gauge how much power they have left. The only common feature its environmental impact shares with the eight-AA option is that it has to be charged with electricity. Many OEMs are therefore turning to
manufacturers of specialist professional batteries for help. At Accutronics, we have helped companies to modify their existing devices to take rechargeable Li- ion battery packs on many occasions. The
“To cope with the rising complexity and varying needs of diverse
industries, T&M firms are increasingly packing their devices with added features, to the detriment of ergonomic design and battery life”
even encounter further disposal charges. The environmental impact is even bigger. Many handheld test and measurement
devices still rely on disposable, single use, cells for power. Manufacturers often use these to keep the price point low, but it can be a false economy. The performance of even the best alkaline cells can fall if the device consumes high levels of current or needs to operate at low temperatures.
RECHARGEABLE BATTERIES So, if disposable alkaline cells are not the answer then what is? The most common choice is Lithium-ion technology, as this provides the highest gravimetric and volumetric energy density of all of the commercially available secondary (rechargeable) battery chemistries. Lithium-ion is safe, provides excellent
cycle life, and is easily fuel gauged, either by an IC within the battery or by one inside the device. It also has
process starts with a custom- built electronic adapter that fits into the battery cavity. Integrated into this adapter is a boost converter, which allows our 3.7V credit card battery to provide the equivalent power, as required. This technique allows OEMs to save the costs associated with bespoke battery development and, at the same time, take advantage of our expertise in battery customisation. When OEMs leave battery development
to the very last moment, they are left with a high value T&M device, costing many thousands of pounds, powered by an inferior power supply. For mission critical applications, therefore, it is essential that the design team takes care to create a sustainable product.
Accutronics
www.accutronics.co.uk
INSTRUMENTATION | SEPTEMBER 2016 31
Neil Oliver
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