Remote operation requires a peak performance battery

summary

Cheap off-the-shelf solutions may be suitable for certain consumer electronic devices with alkali or lithium-ion batteries, especially when the battery is easily replaceable, when operating in medium environments. However, consumer batteries usually do not meet industrial applications needs, particularly those that are difficult to access, extreme environments, and involve large installations where multiple simultaneous battery failures can be very destructive and expensive.

Specifying an ultra-long lithium battery requires detailed due diligence to understand the power requirements and challenges unique to each application. This process can be driven by qualified application engineers who use proprietary data intelligence to help you identify the best power supply solution that provides the best long-term value.

Applications are important

In many cases, the battery specification process is treated as an afterthought rather than an important step in maximizing product performance and cost-effectiveness. Understanding application-specific power needs and verifying battery selection is essential to ensuring reliable operation in remote or extreme environments where replacement is costly or impossible.

Design optimization starts with understanding the unique performance requirements of each application. The answer depends on whether the device is providing backup power, acting as a primary power source, whether it requires extended shelf life, whether the cause calls for a primary cell, or whether it requires energy harvesting in conjunction with a rechargeable lyrion battery. Answers to such questions vary widely depending on the industrial Internet (IIOT) applications such as Supervisory Control and Data Collection (SCADA), Process Control, Robotics, Asset Tracking, Safety Systems, Environmental Monitoring, Machine-to-Machine Monitoring (M2M), Machine Learning (ML), and Wireless Networks.

Important considerations for specifying a battery include electricity, environment, size and weight.

Electrical requirements. Start by knowing your maximum, nominal, and minimum voltage needs. High voltage batteries may reduce the number you need.

Battery capacity measured in ampere hours (AH) determines the maximum theoretical life of a cell based on annual energy consumption. Miniaturization and energy density are essential for miniaturization. Calculating the average current drawn can help you estimate the annual loss of capacity. High pulses should also be considered for advanced features such as bidirectional wireless communication, if necessary. Capacity losses include accounting for storage time and expected losses due to self-draining.

Environmental requirements. Extreme temperatures affect battery performance by reducing capacity, causing voltage drops, and increasing self-discharge rate. Some battery chemistry improves performance under these conditions (see Table 1).

Understanding the operating environment is important for remote wireless devices in extreme conditions. You should calculate the expected temperature during operation and storage, including the time spent in each phase.

Bobbin-type lithium lithium chloride (LISOCL2) batteries offer the widest temperature range (-80°C to 125°C), with the highest capacity and energy density, and can withstand humidity, shock and vibration.

Size and weight requirements. Size and weight limits can affect battery choice. Miniaturization improves logistics and ergonomics by losing space and weight. Small batteries also help reduce the cost of transporting hazardous materials in accordance with UN and IATA regulations.

Structural Integrity Applications

Resensys provides a powerful platform to protect infrastructure systems from aging and malfunctions with remote monitoring (stress), vibration (acceleration), displacement, crack activity, tilt, tilt, temperature and humidity. These precision sensors provide durable and reliable structural monitoring solutions for bridges, tunnels, buildings, dams and cranes.

The Resensys wireless sensor is mounted under the bridge truss (Figure 1) to measure structural stress. These locations are extremely inaccessible, and using bobbin-shaped Lisocl2 batteries can help maximize return on investment by extending operating life and increasing product reliability in harsh environments.

High Pulse for Wireless Communication

Certain low-power remote wireless devices require a high pulse of up to 15 A to power remote wireless communications. Standard bobbin-type LisoCl2 cells cannot provide these pulses due to their low-rate design.

However, a hybrid solution has been developed that combines standard bobbin-type lisocl2 cells for low levels of base current, in conjunction with a patented hybrid layer capacitor (HLC) that generates pulses when needed. As the cell approaches its terminal stage, the HLC shows a voltage plateau indicating “low battery” status.

Consumer devices often use supercapacitors for similar purposes, but are usually inappropriate for industrial applications due to limitations such as short power duration, linear discharge, low capacity, low energy density, and high self-drainage rate. Series-linked supercapacitors require expensive cell balancing circuits and drain excess current, further reducing battery life.

Ask the expert

With remote applications in hard-to-reach locations, an ideal battery-powered solution should continue throughout the lifespan of the device to minimize ownership costs. However, short-term test data often cannot accurately predict long-term performance. Experienced application engineers can help you choose the ideal battery by reviewing power requirements, interpreting test data, and identifying solutions that meet performance standards with minimal trade-offs.

The most reliable indicator of expected battery life is in-field performance data from similar devices operating under comparable conditions. Qualified application engineers can help you identify power management solutions that will extend battery life, improve reliability and maximize return on investment.

This feature was featured in the June/July issue of Automation.com Monthly.

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