• • • BATTERIES&CHARGERS • • •
technical specification. This helps to identify any potential issues in the assembly process or any design flaws. The results are documented in a validation report, which assesses whether the batteries meet the specified requirements. After the validation of prototypes, the manufacturing process moves towards hard tooling. This step involves the production of the components required, which could include injection-moulded plastics, formed metal parts, PCBAs (Printed Circuit Board Assemblies), light pipes, packaging, labels and membrane panels, among other things – tool trials are conducted to ensure the quality and precision of these components. With the production-tooled components ready, a
low volume of non-qualified batteries/chargers is built. These batteries/chargers are assembled using the finalised components, but they are not yet tested to external regulatory standards (if required). Most of this batch is sent to the customer for approval, and the remaining balance is retained at the manufacturing facility for further reference or analysis. Batteries over 100Wh are subject to more costly and complex shipping regulations. To enable volume production, production jigs,
fixtures, test equipment and software is designed and built where necessary. These tools aid in the efficient assembly and testing of the custom batteries/chargers in a larger-scale production environment. Careful consideration is given to ensure accuracy, repeatability and reliability during the manufacturing process.
In preparation for regulatory qualification testing
and certification, components are purchased, and the batteries/chargers are assembled accordingly. Alongside the assembly, all necessary paperwork and documentation are created to meet the requirements of the regulatory bodies. These documents include compliance reports, safety assessments and any other supporting materials mandated by the specific certification tests. The fully assembled batteries, along with the required documentation, are shipped to an external test house that specialises in certification testing. Various tests are conducted to assess the battery’s compliance with industry standards and regulations. Batteries are often tested to UN 38.3 for transportation, as well as IEC 62133-2:2017, UL 62133-2 or UL 2054 for safety. Other tests can include electromagnetic compatibility (EMC), ingress protection, environmental, as well as validations for RoHS, REACH and waste electrical and electronic equipment (WEEE) regulations, among others. Once the custom batteries/chargers successfully pass the regulatory qualification testing and certification, production documentation is generated. This documentation includes detailed instructions, specifications and quality control procedures to guide operators during volume production. Operators are then trained to ensure they have a thorough understanding of the manufacturing process. A small New Product Introduction (NPI) batch is built, part of which is sent to the customer for their
final approval. The remaining NPI batch is either retained at the manufacturing facility in case further amends are needed or safely disposed of if the customer is happy. As the process moves through each of these
stages, from specifying the initial requirements to producing the NPI batch, the cost to both the manufacturer and the customer increases. Therefore, it is important that both parties sign-off each stage and is also the reason why prototype versions of batteries/chargers are shipped to the customer before the finished product. When everyone is satisfied, the project will be completely signed off and volume production will begin (to the agreed levels/dates). Accutronics’ custom batteries and chargers are manufactured at one of three ISO 9001 and ISO 13485 certified facilities in the UK or USA, ensuring the highest quality. In conclusion, custom battery manufacturing
involves a systematic process that encompasses understanding customer requirements, detailed design and prototyping, internal verification, regulatory qualification testing and finally, volume production. Each step contributes to ensuring that the custom battery or charger meets the customer’s specifications, industry standards and regulatory requirements. With a strong emphasis on quality control and adherence to regulations, custom battery manufacturers like Accutronics deliver high-quality, high-performance products tailored to unique and demanding applications.
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smart@atcsemitec.co.uk
TD3305 FT advert - Electronics Today half page 195mm x
135mm.indd 1
electricalengineeringmagazine.co.uk
atcsemitec.co.uk ELECTRICAL ENGINEERING • FEBRUARY2025 13 24/11/2023 15:14 3D PRINTERS
WEARABLE TECHNOLOGY
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0.5mm
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