The Industrial Internet of Things (IIoT) combines connectivity with the ability to virtually monitor and control almost any factory equipment or machinery through interconnected sensors, instruments, and devices.
Using advanced data collection, exchange, analysis, and machine learning, these smart systems help transform operations by increasing efficiency and reliability whilst reducing reliance on human to machine interactions. More efficient machines, automated production processes, and fewer machine breakdowns and lower maintenance costs are thus becoming a source of new growth opportunities. Furthermore, through savings, new revenue streams from useful data, and, sometimes, new business models are possible.
It is no surprise, then, that the IIoT is being widely adopted across all industries, from transportation and energy to the military, aerospace, healthcare, manufacturing, and farming.
Batteries have been an essential asset in the development of the IIoT. But not any battery can do the job. The IIoT uses a range of sensors for measuring temperature, flow, wind, light, vibration, heat, and pressure. These are often deployed in remote locations or mounted on moving assets that can’t be connected to the grid, necessitating a lightweight, compact wireless power solution. This is how batteries have become an essential resource in the development of the IIoT.
But when you deal with an IIoT ecosystem that may be a critical part of the control loop, selecting the right battery is critical. Decisions related to safety, failure analysis and maintenance can only be made if the data is gathered regularly and only if you have complete trust in the sensors and their batteries too.
Batteries intended for use in industrial operations must indeed offer complete reliability under extreme environmental conditions, resistance to vibration and harsh environments. They need to offer a long lifetime (can you imagine the cost of replacing not one, but a thousand batteries spread out on an offshore oil platform, for example?). They must also pass several safety tests and certifications, which can be difficult to obtain. This is why consumer-grade batteries are not an option; you need to consider not just the price but also the quality of the battery you choose for your application.
Saft batteries have been powering the IIoT for many years
IIoT applications usually require very high energy density and high voltage, which are ideally addressed by lithium technology. Indeed, lithium batteries operate at high voltage thanks to the use of lithium as an anode and deliver energy per unit volume that can be ten times that of zinc-oxide batteries. Its electrolyte contains no water, allowing use at low temperatures, and some products with specific electrolytes can withstand high, even very high, temperatures.
Saft has developed a range of lithium batteries specifically intended for the IoT:
• LS, LSH and LSP cylindrical primary lithium batteries based on lithium-thionyl chloride (LiSOCl2) chemistry.
• LM/M cylindrical primary lithium batteries based on lithium manganese dioxide (Li-MnO2) chemistry.
• Medium prismatic MP and cylindrical small VL rechargeable batteries that use lithium-ion (Li-ion) technology.
These batteries have a reputation for reliability and long life in smart metering applications, with hundreds of millions of cells successfully deployed worldwide. Their performance enables intelligent industrial operations for transformational business outcomes. The projects speak for themselves.
Saft LS range for industrial applications
The Saft LS range features high voltage (3.6 V) and high specific energy. The bobbin construction of the cells makes them ideal for applications requiring low continuous or moderate pulsed currents, such as metering devices. Thanks to its exceptionally low self-discharge, the LS range can offer a long lifetime (5 to 20+ years) for applications with a few µA base current and periodic pulses.
Examples of such applications include SRETT’s BumbleBee sensor, a wireless IoT monitoring solution designed to measure and optimise pressure and temperature in ATEX environments. For this turnkey product, SRETT needed a long-lasting, autonomous, reliable battery solution that complied with ATEX requirements.
The LS 14500 offers extremely high-energy density and a low discharge rate. It complies with IEC60086-4 and IEC60079-11 safety standards, and offers enhanced resistance to moisture, corrosion, and flames. It was therefore selected for the application. Thanks to Saft LS 14500 batteries, the sensor can operate over a wide temperature range—certified up to T4 +60°C in ATEX environments and guarantees stable performance throughout the device’s lifetime.
Another such ATEX solution is TWTG’s Neon Valve Sensors, which bring together sensors, mobile communication, and large system integration to create a safer, sustainable, and more productive working environment. Requirements for the device's battery included an extended ambient temperature range of -40°C to +80°C, combined with cutting-edge low-power engineering. A minimum of 3 years' battery life was needed to ensure reliability, and the price had to be competitive in the market.
TWTG spent many hours testing various battery solutions before deciding on Saft’s LS 17500 cell. Saft’s specialised knowledge, ATEX-compliant solutions, and experience working in TWTG’s target markets weren't the only factors that prompted them to choose Saft. Special requests were made to further optimise the traceability of the device’s parts — a key element of the ATEX/IECEx compliance requirements for TWTG’s solution. The Saft teams showed flexibility in responding to these requests.
Saft LSH range for industrial applications
The LSH range features a spiral construction that allows for higher pulse solicitations, as it enhances the delivery of high current, but is only relevant to applications with a 10+ years lifetime, since the delivery of high currents is done at the expense of the cells’ capacity.
Techem, a leading global energy service provider for the real estate industry, created an innovative smart reading system for utility meters, smart heat cost allocators and smoke detectors. The system monitors the device status as well as the heating and water consumption in a building via wirelessly connected devices. For the applications to be enduring and efficient, Techem needed a mature, reliable technology capable of delivering the high pulse currents required for frequent wireless data transmission, even at the end of their life.
The smart meters also had to offer a life expectancy of between 5 and 10 years. After conducting a detailed modelling study based on their device’s specific consumption profile and environment, Saft LSH was chosen, an unrivalled, reliable solution requiring zero maintenance. For Techem, the high level of technical support in selecting the ideal power solution was decisive in choosing the final provider.
Saft LSP range for industrial applications
For longer life applications requiring high pulses, Saft provides customers with the LSP range, which combines a low self discharge Li-SOCl2 cell technology for a long lifetime and a pulse helper (also called a capacitor) to store charge, increasing the necessary voltage and preventing any delay in current delivery.
Saft’s client, Rotecna, equipped its Silotronic silos monitoring systems with Saft LSP Hybrid lithium batteries. The sensor uses laser technology to measure, in real time and remotely the level of feed available in silos. The company wanted to create an IoT device capable of sending level measurements every 2 hours, for 10 years.
As an international supplier of equipment for pig farms, the device had to be able to operate across different temperature profiles. Additionally, the new device had to work at 7,5 V, so the battery solution needed was a 2-cell series (2s1p) configuration (https://saft.com/en/energizing-iot/custom-pack-making-designing-your-iot-batteries-best-standards). The Saft LSP 33600-20F hybrid solution allowed us to assemble this 2s1p configuration without needing to add any protection diode. That proved to be the best technical solution, and the client greatly appreciated the team’s technical support.
Saft LM/M range for industrial applications
The Saft LM/M range of cells features high surface area spiral electrodes offering high power capability (up to 2 A at 20°C for A sizes) and high capacity (up to 3 Ah for A sizes) at operating temperatures between -40°C and +85°C. This makes them a good fit for smart metering devices requiring high pulse rates, as well as for parking sensors and smart farming applications. They exhibit a lower nominal voltage of 3.0 V, compared with 3.6 V for the LS range. If the electronic design of the application allows a cut off voltage below 2.5 V, this range is probably one of the most economic options with a good trade-off between energy and power.
The LM batteries were chosen by XTel, a Danish research and development company, to power some components of their product, Moviot. This versatile product platform enables IoT developers to quickly design a full IoT solution and embed it in their products. Hardware components (gateways, NFC readers, and various smart sensors) are proposed as off the shelf products that can be tailored to developers’ specific needs.
To power such a device, with no exact knowledge of how or where it would be used, XTel needed an adaptable solution capable of withstanding a wide range of temperatures and deployment conditions.
After conducting numerous tests, XTel chose Saft’s LM 17500 to power the wireless gateway, a high-pulse-rate battery that delivers instant network connectivity. The gateway offers 8 to 10 years lifetime in the field, 30-40% more than it used to with competitors’ products. To date, the devices have given complete satisfaction to XTel’s customers.
Alstom Transport also chose the LM range for their mission-critical IoT predictive maintenance application. Intended for rail transport, this IoT solution offers real-time monitoring of crucial components in high-speed trains, including rotating elements such as axle boxes, gearboxes, blowers, motor bearings, and wheels. The device inspects trains using a network of intelligent wireless sensors that capture the acceleration of rotating machines and trigger specific analyses based on maintenance needs.
Alstom Transport needed a ruggedised solution compatible with high vibration environments and extreme temperatures, capable of delivering high peak current power supplies to enable frequent data communication whilst offering a minimum 3-year battery lifetime. Saft designed a customised battery solution using Saft’s LM 17500 batteries that delivered on all fronts.
Saft medium prismatic MP and cylindrical small VL rechargeable cells for industrial applications
Last but not least, Saft medium prismatic MP and cylindrical small VL rechargeable cells are designed for demanding applications that are frequently used in industrial and critical environments. They can be charged and discharged over a wide temperature range for a high cycle count (up to 2800 times with only a 30% capacity loss) and low maintenance. They offer unique performance in unregulated outdoor conditions, including extreme heat or cold.
Fuji Tecom is using Saft VL 34570 XLR in their innovative water leakage detector. The “Quatro Core” LC-5000 can automatically pinpoint the location of a leak by calculating the time difference in the detected noise caused by water leakage across several sensors.
The water leakage detector is used outdoors under various temperature conditions, so Fuji Tecom wanted a robust, wide temperature range rechargeable battery with maximum capacity in a compact format for the sensor modules to be installed anywhere, even in the smallest of subterranean spaces. From a safety point of view, the battery system obviously had to be high quality and secure.
Saft’s small cylindrical VL 34570 rechargeable cells, with their high nominal capacities, long cycle life, and ability to be charged and discharged over a wide temperature range, especially at very low temperatures, made them the ready made solution for Fuji Tecom.
For more information contact Uniross,
| Tel: | +27 11 466 1156 |
| Email: | [email protected] |
| www: | www.uniross.co.za |
| Articles: | More information and articles about Uniross Batteries |
© Technews Publishing (Pty) Ltd | All Rights Reserved
printer friendly version