FEATURE TEST & MEASUREMENT
TEST AND INSTRUMENTATION IN MISSION CRITICAL APPLICATIONS
The total value of products and services in the test and measurement (T&M) industry is more than $130bn, according to research by KPMG. The market continues to grow, driven by increasing complexity, shorter product life cycles, tighter regulation and the demand for high efficiency and cost savings. As a result, manufacturers are packing single, multiple-use T&M devices with features. Here Neil Oliver, technical marketing manager at Accutronics, considers the impact on sustainable design and battery-powered test equipment
T
he chances are that all of the electrical products that you've touched today were
made by machines that were, in turn, calibrated using some form of test and measurement device. From mobile phones and televisions to toasters and cars, everything underwent a series of production calibration routines to ensure the OEM manufactured them to within acceptable tolerances and with appropriate functionality. But if production equipment becomes
decalibrated over time, it can result in quality control errors that can lead to finished products not being up to standard. In these environments, test and measurement equipment serves the purpose of emulating real world conditions so that engineers can deliver products they know are fit for purpose. Although technological innovation has
allowed devices to operate in complex applications, manufacturers still supply some of these units with eight AA batteries. Under normal use, a set of these batteries will last only a day before the failing device requires a replacement. Traditionally, 1.5V alkaline cells have been designed into devices so that the OEM doesn't need to supply a rechargeable Lithium-ion (Li-ion) battery pack. The major problem with alkaline batteries is that, although they provide a good volumetric and gravimetric energy density, they have a very poor power capability. The ability of alkaline cells to provide continuous high power is poor. Add to this the fact that you cannot recharge them and the long-term return on investment (ROI) of using alkaline batteries is far lower than Li-ion batteries. 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. The market for digital cameras provides a good comparison. At one time, all digital point and shoot (POS) cameras were designed to use alkaline AA cells but the demands of the flash and motor drive meant they soon migrated to rechargeable lithium-ion, as
10 JULY-AUGUST 2016 | ELECTRONICS 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 the fact that it has to be charged with electricity.
Figure 1:
consumers were unhappy with spending a fortune on AA cells. What is more, alkaline cells always let you down when you need them most, despite what you may see in advertisements.
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. Lithium ion has 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.
Figure 1:
Accutronics offers help to modify existing devices to take rechargeable Li-ion battery packs
SPECIALIST HELP Accutronics has a wealth of experience designing and manufacturing batteries and chargers for test and measurement devices. The company’s credit card batteries provide a fast, cost effective route to market as each is available off the shelf, pre-tested to all relevant transportation and safety standards. These credit card batteries come in three different sizes and chargers are available so that batteries can be quickly charged outside the device. It is not surprising then that many OEMs are turning to manufacturers of specialist professional batteries for help. It is possible to modify existing devices to take rechargeable Li-ion battery packs. The process starts with a custom-built electronic adapter that fits into the battery cavity. Integrated into this adapter is a boost converter, which allows a 3.7V credit card battery to provide the equivalent power, as required. This technique can help save on the associated costs with bespoke battery development or where OEMs are left with a high value T&M device, costing many thousands of pounds, powered by an inferior power supply. For mission critical applications, it is essential to take care in creating a sustainable product. So, the next time you are enjoying toast for breakfast, produced in a device with a perfect timer attached, spare a thought for the labour of love that goes into making your favourite electrical devices. Consider the fact that an industry worth $130bn exists to ensure the correct toastiness of your morning bread.
Accutronics
www.accutronics.co.uk T: 01782 566622
/ ELECTRONICS
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