Medical Technology Q&A

Rob Phillips, managing director of professional battery manufacturer Accutronics, has identified several key trends that are emerging in the MedTech sector, from rising energy densities to new innovations such as wireless charging. Below he offers his insights into these trends, where he predicts to see the most market growth in the next twelve months and where Accutronics fits into the industry.

Who are you and what do you do? 
I'm Rob Phillips, managing director of Accutronics Ltd. Accutronics is a successful independent battery business serving specialist OEM’s in the Medical Device market and similar sectors, specialising in developing and manufacturing high-performance smart battery & charger systems.
We have an excellent portfolio of demanding OEM customers, who enjoy a real competitive advantage from their long-term partnerships with us.

As well as the medical and healthcare sector, our smart batteries are used in defence and security, as well as industrial test and instrumentation sectors. From small credit-card sized batteries for use in wearable medical devices to intelligent power vaults for use in high-power, high-discharge environments in hospitals, we make them all.

Some of our technical achievements include class leading protection circuits that prevent batteries from over charging, over discharging and overheating, as well as algorithmic security that prevents fake batteries from being used in life-critical medical applications.


How would you sum up your company?
Accutronics enables forward-thinking MedTech companies to create and deliver the next generation of portable medical devices.

As a leading battery manufacturer, we're dedicated to helping overcome new challenges including the use of portable devices in extreme environments, as well as improved battery security aimed at eliminating counterfeits. To do this, we've brought together a passionate team of designers, engineers and market specialists to apply their expertise in creating the battery solutions of tomorrow.

Name a business achievement you are most proud of?
Having grown the company from a startup in 2009, during one of the worst recessions in history, Accutronics is now a first-choice partner for some of the world's leading MedTech OEMs. This is something we're really proud of.


What excites you about this industry?
The environment of constant innovation is enthralling. Knowing that all these efforts are aimed at improving people's lives and the quality of their health makes this a very rewarding industry to be in. On top of this, there are real opportunities open to smaller and medium-sized companies to play a significant role in this innovation.

We've identified several key trends in the MedTech sector: battery energy densities are rising, as more and more equipment is becoming mobile; security is a big concern, especially when it comes to counterfeit batteries; the demand for premium medical devices in the Asian MedTech sector is growing rapidly; new innovations such as fast and wireless charging are on the rise; and finally, the development of antimicrobial polymers and surfaces is providing an extra line of defence against superbugs.


Where do you predict industry growth will come from over the next 12 months?
The BRIC countries, Brazil, Russia, India and China, are widely recognised as being economies with the fastest growing infrastructure in areas such as health service assets, transportation and specifically portable medical devices, which will deliver increased flexibility and value to healthcare users. This is where we expect most of the growth to come from.


Which medical device do you wish you had invented and why?
The plastic syringe, as it's one of the most versatile products. It's more robust and lighter than glass. It's much cheaper to manufacture, there must have been millions manufactured already. Products like the plastic syringe offer a lot of scope for use in the field and are indispensable in places like Africa where the logistics of medical equipment can be very challenging.

Analogue infrastructure needn’t hold you back

Thanks to the digital revolution, technology in both our personal and professional lives is getting smaller and more powerful. For instance, new smart watches have more computing power than the Apollo moon landing space craft! The same applies to medical equipment; hospitals are replacing bulky analogue machines with more svelte, powerful devices. However, the march of digital technology through healthcare facilities is bound by the existing infrastructure, which was developed for analogue solutions, creating unique challenges for battery equipment.

At Accutronics we’re seeing an increase in demand from the medical sector for thinner batteries to be used in new or updated equipment. While advanced technology is a key driver for this, another reason is the fact that original equipment manufacturers (OEMs) have to design machines that fit into an analogue legacy system.

For instance, in new digital x-ray machines there is only 15mm of space for a battery – the space that was set aside for photographic slides in outdated apparatus. This is because hospitals need new devices to fit into the same space as the old ones. So, development of new technology is being shaped by the infrastructure that has been established for low-tech requirements.

In addition, hospital buildings themselves contribute to space saving needs. While there are modern hospital buildings in the UK, there are also those that were built as far back as the 1800s. Mobile devices and carts have to be designed with manoeuvrability around narrow corridors in mind. Therefore, the components inside modern devices are packed tightly together, leaving no room for large battery packs.

Retrofitting or retrospectively designing systems like this creates interesting challenges when it comes to providing a suitable battery to meet both size and power requirements. It’s frustrating enough when your smartphone battery can’t keep up with your usage, but in the healthcare field interrupted power supplies can cause serious problems.

This means that Accutronics often supplies batteries with very thin section walls, as little as 0.8mm, to allow as much space as possible for the cells. Currently, the size of a battery cell can’t be reduced by all that much without losing power, so in very tight spaces you end up having to compromise the capacity of the battery by using fewer cells.

The key to success is for OEMs to consider the battery earlier in the design process. That’s why Accutronics encourages early engagement for all of its clients. While our bespoke battery solutions can be tailored to almost any situation, the earlier in the design our teams can get involved, the easier it is to ensure optimum performance for requirements.

Accutronics works with its clients to create truly outstanding battery solutions, which provide tangible end user benefits such as low weight, minimal volume and ease of use. This is often achieved via our custom battery and charger design and manufacturing service, Accupro, which integrates seamlessly into OEM device development programmes. Some of our batteries even have more advanced control systems than the Apollo 11, which was about as complex as a modern toaster. It's just our way of staying ahead of the curve!

The next-generation of portable power - Inspired Energy boosts the capacity of its standard smart batteries

The industry demand for longer running, smaller and lighter handheld equipment has prompted USA based battery manufacturer Inspired Energy to launch the HD34 range of high capacity Lithium-ion (Li-ion) smart batteries. These batteries use the latest innovations in cell technology to offer outstanding volumetric and gravimetric energy density resulting in longer run-times.

The batteries use the latest Lithium-ion cells with an increased capacity of 3.4Ah to provide customers with a longer runtime.

“The batteries use '18650' cells, which are the workhorses of the rechargeable battery world," explained Neil Oliver, technical marketing manager at Accutronics, the sole distributor for Inspired Energy. “Over the last 25 years Lithium-ion technology has improved and the capacity has steadily increased threefold, resulting in the latest high capacity 3.4Ah version."

Batteries using the 3.4Ah cells are available in two, three, four, six and eight cell configurations covering 7.2V, 10.8V and 14.4V outputs, so original equipment manufacturers (OEMs) developing new products can be confident in finding a platform that meets their mechanical and electrical requirements.

A wide variety of applications make use of the Inspired Energy batteries, including portable laboratory equipment and medical patient monitoring devices, hand-held data terminals, unmanned underwater vehicles, professional and broadcast cameras and satellite communication.

Lithium-ion batteries must be transported as dangerous goods, requiring batteries to be subjected to testing. The companies offering such products for transport are subject to strict packaging, labelling and paperwork requirements. Shipping of Inspired Energy Lithium-ion smart batteries is made easier as they have already been tested for transport and all have an energy density under 100Wh reducing the level of paperwork and packaging.

The new 3.4Ah cells allow batteries and devices to be made smaller and lighter. Some of the older battery models in the range use twelve 2.2Ah cells to provide 95Wh. When using 3.4Ah cells it is possible to realise this energy with just eight cells. This means the batteries can be made around 30% smaller and lighter, a real benefit to OEMs looking to reduce the size and weight of their devices, while still providing maximum runtime to users.

Inspired Energy standard smart batteries can be customised to meet the need of the customer, including changing the artwork to carry own-brand labels and modifying the smart battery data. Accutronics designs and manufactures its own range of batteries and chargers, but is also the sole distributor of the Inspired Energy range of standard batteries, chargers and accessories.

Having worked with Inspired Energy for over 20 years, Accutronics offers multi-currency pricing, online purchasing, European stock holding and fast customer support from its headquarters in the UK. Accutronics technical support service ensures that customers can design an Inspired Energy battery into their new device with total confidence. 

Charging ahead with medical devices

~ Hi-tech medical equipment goes portable with new energy-dense battery ~

Independent battery design, development and manufacturing expert Accutronics has launched a new smart battery that fulfils the needs of manufacturers of high powered medical devices. The CMX series packs a punch - offering high energy density along with high power discharge. Medical OEMs (Original Equipment Manufacturers) can now produce innovative portable devices without compromising on safety and reliability in life-critical applications.

The medical market is a challenging environment, and understandably so. With people's lives on the line it is essential that medical practitioners can rely on their equipment to perform under pressure. The rise in the use of portable devices such as acute ventilators, anaesthesia workstations and intra-oral scanners over the last twelve months has left many medical OEMs struggling to keep pace in the market.

“Part of our branded Entellion range, the CMX meets stringent regulations, demanding development schedules and innovation aims, whilst minimising unit costs," explained Neil Oliver, technical marketing manager at Accutronics.

The battery is available in three versions, using eight, twelve or sixteen '18650' sized cells, with continuous discharge rates of up to 300W. Two voltage platforms are used; 28.8V, which operates between 20.0V and 33.6V and 14.4V, which operates between 10.0V and 16.8V.

Smart features of the CMX series include active and passive protection circuits that prevent over-temperature, over and under-voltage, overload and short circuit.

Forming an essential part of its medical device operation, smart power management means the battery only requests charge when needed and shuts down when not being used. Accurate fuel gauging is possible to 1% through an LCD display, further enhancing reliability.

The new battery complies with the relevant transport regulation, which exists to eliminate the risk of explosion associated with the transport of such energy dense cargo. The CMX series complies with transportation (UN 38.3) and safety (UL2054 2nd ed. and IEC61233:2012) as well as electromagnetic compatibility (EMC) regulations (CE and FCC).

The range charges between zero and +40 degrees, discharges between -10 and +50 degrees and can be stored between -20 and +60 degrees. This results in 500 cycles of 80% minimum rated capacity.

Hospitals can now perform routine power management checks without having to remove the medical device from service using the smart charger that accompanies the CMX battery. A single charger can be used for different sized batteries, because the two devices automatically communicate exact voltage requirements.

For customer convenience, two chargers are available to accompany the CMX series, an internal single channel charger and an external dual bay desktop charger, which can also be used for battery calibration.

Whether batteries or chargers, the Entellion range is made to be customised. Options include product labelling and case colours, software setup and SHA-1 algorithmic security, which prevents counterfeit batteries being used under fraudulent warranty claims.

High-five for high-power

Tackling the rise in demand for portable medical devices delivering high-rate power discharge, battery specialist Accutronics will be launching a new CMX range on 12 November, 2014 at COMPAMED, the international medical trade show held in Dusseldorf, Germany. In anticipation of the launch, we explore the world of portable power.

Speed is of the essence in life-critical applications. Usually, ambulance crews will transport heart-attack patients to the hospital's emergency ward as soon as possible. However, a leading UK Accident & Emergency doctor recently called for patients to be treated by paramedics until their heart starts beating or they die.

Writing in the British Medical Journal, Dr Benger says that it, "may be actively harmful" to rush cardiac arrest patients to hospital. Because there is only a short time-window of around 50 minutes before permanent brain damage sets in, it is vital that treatment is provided quickly and effectively.

The last few years have seen an increased demand in mobile technology used in hospitals and in the field. Specialised stroke emergency mobile (STEMO) ambulances fitted with portable CT scanners cut the alarm-to-treatment period to just 25 minutes. Acute ventilators, portable anaesthesia workstations and intra-oral scanners are other examples of medical equipment breaking free from the traditional mains power supply.

However, the challenge with these devices is the high-rate power delivery required to operate reliably. The recent Ebola outbreak in West Africa has highlighted the challenge of transporting patients from one part of the world to another. Medical equipment used in the transport of patients must be capable of operating with limited resource for electricity, water and compressed gas.

On September 4, 2014, in response to the Ebola outbreak, the World Health Organisation (WHO) issued guidelines for medical equipment donated for use in the field. The guidelines reinforce the necessity for devices to use high-quality backup power, with current stabilisation, surge protection and uninterrupted power supplies to protect against blackouts and unsustainable mains power.

To overcome these problems, here at Accutronics we've developed a new CMX smart-battery range specifically for high-power applications. Capable of accurate fuel gauging, built to international regulatory standards (IEC62133, UL2054) and offering device-to-host communication for continuous swappable power, the new range will be especially useful in the increasingly dynamic nature of modern hospital care.

Visitors to COMPAMED can find out more about how the CMX range will revolutionise the mobile medical market at Accutronics' product launch press conference. The event will be held at 3pm on the 12th of November, 2014 in room 801a off hall 8b at COMPAMED. Alternatively you can view and discuss the new product range in Hall 8b Stand F30 where Accutronics will be exhibiting. If you're interested in attending, you can register for free by calling 01785 225416 today.

If you’re unable to make it to COMPAMED, we will also be launching and displaying the new CMX series at ELECTRONICA in Munich between 11th and 14th November in Hall B2 Stand Booth 454.

Things you thought you knew about batteries

They are the most readily available source of power for our army of portable devices. They provide us with precious energy, right down to the last milliamp. They are invariably unavailable in your local garage on Christmas Day. I am, of course, talking about batteries. But what do we really know about the professional application of this most ubiquitous of products? Here we bust some myths and shed some light on the most commonly held misconceptions about batteries in professional applications.

1. I need to fully charge my new device before first usage - FALSE

First you spend countless hours in the shops hunting down the perfect device, it may be a new laptop, phone or camera. You rush home, rip away the packaging like an excited child on Christmas morning and turn on your device, only to find instructions telling you to 'ensure the battery is fully charged before first use'.

The same is true in many professional applications, with even experienced end users still believing they need to charge the device fully before first use.

Whilst this was true once, the advent of modern Lithium-ion (Li-ion) battery technology means that devices can be used straight away without harming the battery.

So why do many manufacturers still print the warning? It seems this is a marketing and reputation management tactic more than anything else; to ensure that customers have the most engaging first interaction. That wouldn't be the case if your battery died within five minutes of use!

However, the nature of Li-ion batteries means that certain precautions do have to be taken during the shipping process. Li-ion batteries must retain a minimum charge to prevent them becoming unstable. When not in use, the onboard microcontroller, which itself consumes around 5% of charge per year, ensures that the battery is turned off before complete discharge.

Conversely, shipping a fully charged battery can also be dangerous as such a high volume of energy is not safe during transit or good for battery cells. This is why most original equipment manufacturers (OEMs) charge batteries to around 50% for transit.

Here at Accutronics, we use a special sleep-mode for shipping. This ensures that the battery exhibits negligible power consumption during shipping, recovering full functionality when first powered on. If you want to know more about it, get in touch.

Accutronics' credit card battery provides vital power to portable medical devices

2. I must discharge my battery fully, before recharging each time - FALSE

This myth was a reality in the 70s and 80s when Nickel Cadmium (NiCd) and Nickel-Metal Hydride (NiMH) batteries were commonly used. The active materials used in these batteries meant that, when put on charge, a cell's capacity was limited to the previous discharge level. This problem was overcome by fully discharging the battery each time.

The memory effect has been all but eradicated with the use of modern Li-ion batteries, which should only be discharged to around 20% before being recharged.

This doesn't mean that batteries don't degrade over time. A typical Li-ion battery has around 300-500 optimum cycles before it starts to lose capacity. However it is not necessary to start each cycle after a full charge and discharge. A cycle can equally go between half full and half empty; how's that for philosophical battery debate!

So, it turns out that some of the things you thought you knew about batteries were false and some of those myths actually create more questions than they provide answers. If you want to really get to the bottom of how to charge, transport and manage batteries in professional and medical applications, get in touch. We have a whole team of myth busters ready to help.

Batteries préassemblées pour une mise sur le marché plus rapide

Entellion batteries

Accutronics, spécialiste indépendant de la conception, du développement et de la fabrication de batteries et de chargeurs, a lancé Entellion, nouvelle gamme de produits d'alimentation intelligents et novateurs conçus pour répondre aux besoins des appareils professionnels aux multiples fonctions.

Entellion regroupe l'expertise de l'entreprise en fabrication de batteries OEM à sa connaissance approfondie des besoins des produits professionnels OEM et des tendances du marché. Les produits Entellion sont proposés dans le commerce et peuvent être également personnalisés pour accélérer la mise sur le marché d'appareils électroniques portables par leurs fabricants qui réalisent ainsi leurs objectifs.

Les premiers produits préassemblés étaient les batteries lithium ion de format carte de crédit CC2300 et CC3800, qui permettent aux ingénieurs de conception d'intégrer une petite batterie au nouveau produit portable avec un minimum d'effort et à moindre coût. Ces produits ont été conçus pour de hauts niveaux de fonctionnalité et de sécurité, réduisant ainsi le délai de mise sur le marché, tout en éliminant les coûts associés à l'outillage et à la qualification.

Les produits plus récents sont les batteries lithium ion intelligentes standard de la série VR qui présentent le tout dernier SMBus de suivi de l'impédance et les jauges conformes SBS, l'indicateur de charge à cinq DEL, un boîtier robuste, une interface à connecteur six directions et des glissières pour une insertion aisée dans l'appareil. Toutes les batteries sont assorties des agréments UN38.3 (transport), IEC62133 et UL2054 (sécurité) de série, et sont par conséquent prêtes à l'insertion dans les appareils avec un minimum d'effort et à moindre coût.

L'entreprise travaille en collaboration indépendante avec les plus grands fabricants mondiaux d'éléments de batteries, pour sélectionner l'élément adapté à chaque application, en optimisant les caractéristiques telles que la capacité, le régime, le cycle de vie et la performance thermique.

La technologie rechargeable lithium ion (Li-ion) est la plus utilisée dans les appareils électroniques portables. Par sa densité d'énergie massique et volumétrique supérieure, la technologie lithium ion assure des durées d'utilisation plus importantes et des poids moindres en comparaison aux combinaisons plus anciennes que sont le nickel cadmium (NiCad), le nickel-métal-hydrure (Ni-MH) et le plomb.

« Dans un monde dominé par les appareils électroniques portables, il est essentiel de pouvoir gérer l'alimentation par batterie », explique Rob Phillips, directeur général d'Accutronics. « Ces systèmes électroniques intelligents intégrés permettent aux batteries de gérer leur propre chargement efficacement et de manière sûre, tandis que les jauges internes donnent au matériel hôte les informations exactes en temps réel. »

Custom batteries

At Accutronics, we have standard batteries to suit almost any new portable device, but we also recognise that many applications are unable to accommodate standard batteries and require a custom battery to be designed instead. 

To this end, Accutronics has rebranded its design and manufacturing activities as Accupro, a service which provides both custom batteries and chargers to OEMs in professional markets.

When standard off-the-shelf batteries will not suffice, most battery manufacturers will suggest modifications to a product’s design. At Accutronics however, we work with the OEM to create truly outstanding battery solutions which provide tangible end user benefits in terms of low weight, minimal volume and ease of use.

Correct cell selection is critical in achieving optimal battery and device performance and we can help customers select the right cell for each application, optimising characteristics such as capacity, rate capability, cycle life and thermal performance.

Whilst batteries come in all shapes and sizes and a range of chemistries, you may often need a solution tailored to meet a specific application need.

With the Accupro service, Accutronics offer all of the commercially available rechargeable battery chemistries, but it is Lithium ion proves most popular given its high degree of safety and high volumetric and gravimetric energy density. Depending on the requirements of the application, Accutronics engineers will select from cells with different cathode formulations to provide the best mix of performance attributes. Cathode formations such as pure cobalt (LiCoO2) for high energy, Nickel Manganese Cobalt (Li(NiMnCo)O2) for rate capability, safety and cost or Iron Phosphate (LiFePO4) for outstanding cycle life and power delivery are amongst the selections available to Accutronics engineers when developing any new battery under the Accupro brand.

Accupro embedded intelligent electronic systems allow batteries to manage their own charging both efficiently and safely while on-board fuel gauges provide equipment with accurate real time runtime information to ensure the best performance from your battery.

Accupro caters for all sizes of battery, from the smallest single cell solution with simple electronic protection through to large high voltage batteries with active cell balancing, impedance tracking fuel gauging and tiered protection systems. There are no brown-outs at peaks of demand, no failure of critical components at extremes of temperature and no oversized PCBs taking up space and making the battery (and your device) larger than it needs to be.

Accupro uses the latest digital prototyping techniques to get the design to market quickly. Accutronics performs finite element analysis (FEA) of the CAD models and employs 3D printing technologies such as stereolithography (SLA) or selective laser sintering (SLS) equipment to generate physical prototypes. Mould flow simulation is used to test and validate the injection moulding design prior to tooling.

Smart-battery manufacturer to exhibit at Med-Tech

The Intelligent Power Vault battery

Accutronics, the Midlands-based battery specialist will showcase leading-edge battery and charger products at Med-Tech Innovation Expo 2013 to be held at the Ricoh Arena, Coventry, UK on April 10-11, 2013. The company’s star exhibit on Stand 13 will be the recently launched Intelligent Power Vault Lithium-Ion multi-battery power system for medical applications.

Intelligent Power Vault (IPV) is a battery system that powers medical devices when high energy density, reliability and functionality are critical requirements.

Available in configurations between 126Wh and 1.42kWh, IPV draws power from multiple 63Wh or 89Wh VR420 Lithium-Ion smart batteries, which are inserted into the IPV's innovative racking system. DC power is available either as raw battery voltage or regulated to suit medical customer requirements.

The IPV also provides a wealth of vital battery data to its host equipment via its USB and serial interfaces - ensuring that data such as remaining runtime is reported accurately and efficiently.

The Entellion off-the-shelf range of battery products will also be on show. These products combine the company’s expertise in custom OEM battery design with its understanding of professional OEM requirements and market trends. Entellion products can be customised, allowing manufacturers to reach their markets quickly and confidently.

Additionally, visitors to the stand will see examples of the Accupro specialist custom batteries and chargers that the company has developed for some of the world’s leading medical device OEM’s.

Rob Phillips of Accutronics
will present a paper
at MedTech

Rob Phillips, managing director of Accutronics will be presenting a paper on the subject of Harnessing battery innovation for next-generation medical devices. Rob will speak at the Exhibitor Zone at the show at 11:30 on April 11.

“Medical device design has always been a key sector for our energy products,” said Rob. “Meeting leading OEMs, designers, integrators and device manufacturers will present numerous innovations and relationship building opportunities, so we look forward to taking part in this exciting event,” he concluded.

Newly appointed direct sales and marketing manager subscribes to better for all life philosophy

Michele Windsor

Midlands based battery manufacturer Accutronics has appointed Michele Windsor as direct sales and marketing manager. In her new role, Windsor will focus on building the e-commerce functionality of the company’s website and marketing the company’s products across Europe.

Accutronics delivers smart battery technology to OEMs (Original Equipment Manufacturers) worldwide, to a range of industries, including military, medical, industrial and portable electronics applications.

The company offers ‘whole of life’ support for OEMs and design consultants who demand a high level of technical and commercial expertise. The smart batteries offer advanced functionality and performance and features such as charge control, fuel gauging and device communication.

With twelve years of experience in direct marketing and sales at hand-held radio distributor CS Electronics, Michele will make use of her broad sales experience in her new role at Accutronics. Her responsibilities will include in-house marketing, website content management, customer relations management and event organisation.

“The intricacy of the activities going on in the Accutronics factory is amazing,” enthused Michele. “Unfortunately, many people don’t realise the level of technological innovation that goes into the manufacture of smart batteries. My aim is to further raise awareness about their benefits in anything from life saving medical applications to military equipment. I am a firm believer in the better for all life philosophy, so my work here fits in perfectly with that school of thought,” she concluded.

“Having worked in almost all areas of the electronics industry, Michele boasts a great deal of knowledge in manufacturing processes and technologies,” explained Rob Phillips, Accutronics’ managing director. “Her role is a varied one, but I am confident that her expertise can bring value to our current projects such as re-branding and advertising our Inspired Energy range of products,” he said. 

Passionate about exercising and extreme sports, Michelle adores skiing, water boarding, skydive and acrobatic flights.

Research success celebrated in local Knowledge Transfer Partnership Award

Midlands based battery manufacturer Accutronics has won a Knowledge Transfer Partnership Award for an innovative research project conducted together with Aston University. The national technology and innovation programme, run by the UK’s Technology Strategy Board and, led by Prabhjit Singh Chugh, operational strategy engineer, offered valuable results from research into the custom battery design processes.

Pictured (left to right Dr Ming Lim, Dr. Russ  Bromley, Gareth Hancox and Dr. Doug Love.

 A Knowledge Transfer Partnership (KTP) is a Technology Strategy Board Programme intended to promote and support research into the development and exploitation of technology and innovation for the benefit of UK business, in order to increase economic growth and improve quality of life.

“Under the terms of the scheme, Prabhjit is an employee of the University who works, to all intents and purposes, as a member of the team at Accutronics,” explained Martin May of Aston University. “His role is to present a project in partnership with the host business to attract Government funding. The University provides some supervision and mentorship, as, of course, does Accutronics. This project is one of several in the West Midlands part funded by a grant from the European Research Development Fund.”
“Accutronics has provided immense support in developing and implementing a new customer driven approach towards operational strategy development,” said Prabjit. “The KTP partnership between Aston University and Accutronics has made it possible to convert academic advancements into a practical business tool which will continuously provide benefits to the business even beyond the life of the project. Furthermore, Accutronics, an excellent host company, have supported me in developing a new approach to managing operational improvements in a very customer-driven way,” he concluded.

Prabhjit and his team also developed ways of increasing supply chain efficiency; improving the reliability of supply to customers and to reducing costs. Key achievements in the first year of the project have included the definition of operations performance targets for existing and new markets and the identification of over one hundred improvement actions in the business process. 

“The two year KTP project was aimed at developing and implementing an operational strategy, together with all necessary processes and facilities to support a growing and increasingly complex product range within Accutronics,” explained Gareth Hancox, company supervisor for the KTP Project. “It is now in its advanced stages and we’re confident it will further improve Accutronics’ reputation amongst our customers, allowing us to deliver products in accordance with challenging performance requirements.”

“The KTP programme unites academic rigour and applied thinking with the realities of practical business challenges in a very effective way.  It is part of Accutronics’ innovation programme, intended to continually bring new technology and innovative solutions to our products and processes,” enthused Rob Phillips, Accutronics’ managing director and facilitator of the KTP project.

What Accutronics really does in industry

When industrial equipment has to operate without a mains electricity supply, OEMs need to find sustainable alternatives to ensure continuation of plant activity at all times. As a consequence, the manufacturers turning to us are looking for battery solutions that will give their equipment a real power advantage over the competition.

Robots require emergency power

Power back up is a vital part of an emergency shutdown strategy in industry, especially if there are high levels of automation in the plant. Accutronics supplies batteries for applications such as industrial robots, power monitoring equipment and door entry systems. In each of these instances, the provision of emergency power in the event of a problem with the mains supply is essential as none of them can afford to be inoperable during the time between the loss of supply and the continuity provided by the diesel generator.

One simply can’t afford to have a robot moving in an uncontrolled way in the cell or a door locked in the closed position while you wait for the emergency power to kick in. In an industrial environment, batteries are crucial for the safety of operators and plant activity. If the electricity connection fails, the reliable smart batteries are there to take over with minimum disruption.

Many of our industrial projects can be used in a variety of applications, from oceanographic monitoring to vehicle emission testers and tracking systems. We understand that each of these dedicated battery designs need to provide the most cost effective solution over the lifetime of the application. 

Ahead of the market
Accutronics continually strives to stay ahead of the market in the development of intelligent battery solutions. For example, we continually improve the integration of fuel gauging electronics, active protection circuits and cell balancing into batteries to provide class leading functionality. 

Over three decades of experience in developing and manufacturing rechargeable battery solutions for OEMs worldwide has given the Accutronics team an in-depth understanding of industrial equipment requirements. This is really important because too many battery manufacturers get lost in the minutiae of following the design brief, building the battery and then shipping it to the customer.

However, at Accutronics we like to regard your project holistically, taking into account every detail which affects the running of the application. We don’t just design batteries; we offer whole of life support and advice, from discussing your ideas to implementing the customized battery into the application.

In addition, our consultants ensure that any newly designed energy solution is compliant with European, as well as industry specific regulations. Safety issues are high on our agenda and all off the shelf and customized batteries undergo thorough testing.     

If you have an industrial battery project in mind send us an email at sales@accutronics.co.uk or contact us by telephone on +44 (0) 1782 566688.

Ask Neil – frequently asked professional battery application questions

How do I select the best cell for a custom battery design?
Cell selection depends on a number of factors including cost, weight, available volume, charge time, discharge current, environmental conditions and required service life.

Battery developers have a number of cell types available to them including Nickel Cadmium, Nickel-Metal Hydride, Lithium ion and Lithium ion Polymer. In recent years it is the Lithium ion chemistries that have dominated product development due to their high energy density and reducing cost, but the older Nickel chemistries do still offer superior performance in certain applications.

Yet when designing a customised battery, cell selection needs to be regarded holistically. This means that a decision should be based on individual cell attributes that fit the design best. It is important to remember that no single cell type offers every performance attribute that might be required – there will always have to be a compromise.

What communication methods are there for batteries?
There are a number of different ways of communicating with a battery. Some manufacturers use proprietary protocols, but I believe that an open standard such as the Smart Battery System (SBS) offers the best solution for battery, charger and device manufacturers alike. Using SBS allows all of the actors to develop their own products with the knowledge that they will work seamlessly with each other. Adopting a common standard also allows for ‘chemistry independence’ where chargers that are developed now will work perfectly well with batteries that are developed in the future.

When the world demands higher energy density from its batteries, what are you doing to keep the weight of your products down?
It is a known fact that anything you add around the cells of a battery pack reduces energy density. However it is important to carefully weigh up the need for energy with the need to create a battery solution that is easy and safe to use throughout the life of the product. All components in and around the battery have to add value in some way – if this is to protect against vibration, prevent water ingress or to simply allow the battery to be latched onto the host device they must all play their part. There is little point in creating an integrated electronic protection system for the battery if this is damaged by external mechanical abuse – such a system must be protected in the same way as the cells must be protected – to ensure that safe and reliable operation is maintained under all operating conditions. The use of modern polymer materials can provide both light weight and extreme strength when used correctly. Alternatively, materials such as magnesium can provide enhanced electrical shielding for mission critical applications.

What do I need to know about battery certification?
The days in which a battery pack could be quickly assembled, reviewed by an OEM and then dropped into an application are long gone. Today, most OEM applications require their rechargeable batteries to undergo a level of regulatory testing before they can be used. IEC62133 is already a mandatory requirement of many device standards. For Lithium ion batteries there are additional testing requirements for transportation. Once testing has been done for CE marking and country or application specific testing have been completed you can see that the list of regulatory tests becomes quite long. Accutronics boasts a great deal of experience in having batteries tested to all of these standards. We manage the process seamlessly, ensuring batteries are approved on time and within budget. 

Accutronics partners with Shmuel De-Leon Energy for batteries and fuel cell seminar

Professional battery manufacturer Accutronics has partnered with Shmuel De-Leon Energy to provide a two day 'Batteries and Fuel Cells' training seminar on the 2nd and 3rd of May 2012. Mr De-Leon is a world expert on both batteries and fuel cells and is travelling over from Israel specifically to deliver this seminar, which has previously been delivered in both Europe and the USA.

The batteries and fuel cell seminar is ideal for experts and novices alike

 The Seminar will provide a comprehensive review of current and future electrochemical energy sources. It will cover cells and raw material selection, design, manufacturing, testing, safety, transportation and disposal of energy sources. The seminar programme focuses on present and future needs of portable and stationary electrochemical energy sources and highlights the latest technological developments. Primary, rechargeable, reserve, commercial, industrial and military batteries, fuel cells, ultra capacitor systems and their accessories are all discussed.

Special focus is given to battery design and testing, which are vital tools for battery solutions. The seminar program also reviews the updated status of battery air transportation restrictions and instructs on the safe transport of batteries according to IATA (International Air Transport Association) regulations.

Shmuel De-Leon is a leading international expert in the business of power sources. Prior to founding his company, Shmuel held various positions for over 20 years as a power sources, engineering and quality control team manager.

Shmuel holds a BSc. in mechanical engineering from Tel-Aviv University and an MBA in quality control and reliability engineering from the Technion Institute in Haifa as well as an electronic technician's diploma. Shmuel De-Leon Energy Ltd provides unique tools for the energy sources industry, such as its energy sources database, battery and fuel cells seminars, energy source solutions, industry news weekly newsletter, and consultation services.

Heart of the matter: The real role of the battery in medical and healthcare device design

The heart of the matter: medical

At Accutronics we appreciate that, when sourcing technology for medical device design applications, it’s easy to focus on the finer technical details and lose sight of the tangible value the technology delivers.

We see the real value in the inherent purpose of our professional battery applications as opposed to just the technical functionality, important as that is. To highlight this we are producing a series of blog posts that look beyond the technology at the end use of our products in various industry sectors; starting with batteries for medical and healthcare device design.

The battery is a key component of the medical equipment that allows healthcare delivery to be run in a much more flexible, reliable and efficient manner. Developments in battery technology enable an increasingly supportive and patient centric service. For example, portable back-up power packs can now be used to power home-use medical ventilators, giving patients with respiratory illnesses confidence and security in their own homes.

On X-ray machines, the development of powerful, lightweight batteries has enabled portable versions to be designed. This allows X-rays to be carried out more quickly and cheaper than ever before whilst retaining the same levels of quality. These kinds of devices help medical professionals rapidly and accurately assess the needs of casualty patients.

Our products also power innovation in disease detection. Battery powered Pillcam systems (also known as capsule endoscopy) identify gastro-intestinal disease without the need for surgical procedures, making savings of time, cost and well being.

Finally, our battery and charger systems enable critically ill patients to be transported whilst remaining connected to life-saving monitors and ventilators. Patients would, quite literally, not survive the journey without this essential piece of equipment.

We see Accutronics’ future in the medical design industry as contributing to continued progress and development of the device itself using the application of ever more advanced battery technology. One of the ways we believe we can achieve this is by continually re-focussing on the purpose of the end technology, allowing us to concentrate our technical understanding on helping our customers achieve their objective.

If you want to discuss the development of batteries for the medical sector, please contact our sales and customer service team on +44 (0) 1782 566688 to discuss your requirements.

B is for Banks... and the search for fuel gauge Nirvana

Carl Banks with a Lithium-ion fuel gauge PCB

We’ve all been there... Just as you turn on your laptop to deliver the key presentation of your entire career, the infernal machine runs out of power and you are left with a blank screen. It’s not possible! You checked the power gauge before you left the office and it said 80% remaining!

If you work in the battery industry, you have probably already used exactly this analogy to describe the importance of accurate gauging. It’s certainly a story familiar to Carl Banks, one of Accutronics’ fuel gauging experts. 

Amongst Carl’s key responsibilities is ensuring that all of Accutronics’ batteries are configured to provide the most accurate gauging possible. 

The fuel gauge is a vital part of a professional battery solution. The more accurate it is, the better it can track capacity and the more realistic the device’s predicted run time will be. In mission critical situations, like medical devices and military equipment this can be crucial.

“Of course, there are some applications where the fuel gauge isn’t as important as it is on a medical ventilator or pair of night vision goggles,” explained Carl. “But our customers are leaders in their chosen markets and they demand precise and reliable information whether the battery is brand new or many years old. This is why we test our batteries under various usage scenarios, continually collecting the data that is needed to set-up the fuel gauge.

“The most significant environmental factor that affects fuel gauge accuracy is temperature,” Carl continued. “However, we also have to address non-environmental issues such as charge and discharge rates and cycle life. Put simply, the more the battery is used the more its capacity drops over time, and the fuel gauge must account for this behaviour.”

“We use Texas Instruments’ gauges in many of our products,” Carl went on. “The data we gather from our tests is analysed and used in the programming of the fuel gauges’ FLASH memory. The whole process can take many weeks but it ensures we achieve the best possible precision.”

Carl was keen to emphasise the importance of the ‘impedance tracking’ fuel gauge technology that Accutronics now use in most of their new smart battery developments. This technology allows the battery fuel gauge to continually make adjustments to its remaining capacity prediction - even when the battery is not being used, by measuring the battery impedance during periods of inactivity. Older ‘coulomb counting’ gauges had to ‘learn’ about a battery by establishing the top of charge and discharge limits first. As a result, a battery fuel gauge that uses impedance tracking is more accurate and can be used for longer without needing to be calibrated – this means that customers can rely on the fuel gauge information and don’t need to spend time fully charging and discharging their devices to obtain accurate information.

So, next time you’re sitting in front of a redundant laptop, wishing you had a more accurate power gauge, spare a thought for Carl and his quest for fuel gauge nirvana, which helps ensure that genuinely mission critical applications don’t suffer the same problems as your laptop.

Accutronics shortlisted for major award

Earlier this week we learned that we've been shortlisted for the 2012 British Business Awards in the Small Business of the Year category. We’re really excited about the honour here, so we thought we’d share some details with you. 

The yearly British Business Awards celebrate exceptional performance in business and acknowledge those organisations that have made an impact in their industry sector. With nine different categories, the awards are designed to promote and encourage startups,
SMEs and large companies alike.

Participating enterprises in Small Business of the Year Award have to demonstrate solid success, be it growth or exploiting new products, production techniques, services or markets. The British Business Awards are run in conjunction with the Sentinel newspaper.

Here at Accutronics we have taken an innovative approach to all of our products and quality manufacturing has been at the forefront of our endeavors.

Our entry was covered by the Sentinel and here is what the journalists had to say:

“Today the Newcastle-under-Lyme battery firm, with its Li-on (lithium ion) range is a power house on the world stage (…)Currently employing some 45 people, it is exporting to over 30 countries and is a contender for The Sentinel Business Awards – having been nominated for the Staffordshire University-sponsored Small Business of the Year Award.”

You can read the full article here.

“We are delighted to have been shortlisted for this award,” said Robert Philips, managing director at Accutronics.  “Especially since it’s the first time we’ve entered! I think being shortlisted should be regarded as a reward for the whole team’s effort. We have a great working environment with experienced people here and I think it’s starting to show in achievements like this one. So keep your fingers crossed for us,” he concluded.