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Custom design and
manufacture of state-of-the-art battery chargers, UPS,
and power supplies for OEMs in a hurry!
Technical helps for the
specification of custom battery chargers. We have put this questionnaire
together to help you think through the various options and decisions you can
make. This isn't an exam, just fill in what you can, we can help you supply the
rest!
1. Brief Description: It
helps to know what this charger is to be used for, what unique characteristics
it might have, what the target market is, etc.
2. Dimensions: (Optional)
What size would you like to see? This is important in order for us to decide
whether to use surface mount or through-hole manufacturing, and whether to use
a linear transformer or a high frequency switching power supply.
3. Open Frame: Do you want
a board level product, a complete unit including case and silk screening, or
something in between?
4. Enclosure material: Are
you looking for a steel case, aluminum extrusion, or molded plastic case?
5. Color: (Optional.) We
can paint any style case, anodize aluminum, or use colored plastic.
6. Input voltage: Do you
want 120 VAC 60 Hz, 240 VAC 50 Hz, or universal input? Universal input comes in
two varieties, automatic or switched. If you are going to supply the DC input
for the charger, what voltages are available?
7. Input voltage notes: For
low wattage chargers it often makes sense to use a wall mount power supply (up
to 10 watts or so). These are usually already UL listed, very cheap in price,
and customers are used to using them. For higher power there may also be
off-the-shelf power supply options, but it may be cheaper to integrate a
PowerStream designed power supply into the charger.
8. Power Supply Power:
(Optional.) Usually what is important is the charging power, but if you have an
application that requires a limited input power put that here.
9. Power Supply Efficiency:
This is only occasionally an issue--for example if there is limited power such
as charging from a solar panel, or where heat dissipation is a problem. Higher
efficiency is more expensive and comes in a range of efficiencies versus cost.
Talk to one of our engineers about your needs if this is an issue.
10. Input frequency: 50 Hz,
60, Hz, DC, etc.
11. Battery Type: If you
have chosen a battery type please tell us the details. Every battery
manufacturer has its own preferred charging method. We would like to use the
best charging algorithm. However, if the battery company wants expensive
features that you might not need (for example temperature compensation over a
large temperature range) we will discuss the options with you.
12. Charge time: Charge
time is dependent on the battery type and the charger power. Generally a faster
charger is more expensive because it requires a larger power supply.
13. Output voltage:
Optional. Usually we design the charger to optimize the charge cycle. However,
if you intend to operate your device from the charger during charging, or
without the battery pack, you might need to specify the ripple, noise,
regulation, and protections.
14. Battery discharge
options: This is an option for NiCd batteries only. It conditions the
battery by discharging to a set voltage, before the charging starts.
15. Preferred charging methods:
These are methods to determine the end of charge. Different battery
chemistries and manufacturers require different methods. There is no need to
fill this in, as PowerStream will determine the best way to charge your
battery. If you know exactly what you want please indicate it, or describe it
in the space provided.
16. Battery charger indicators:
Tell us what you want to indicate the charging status. Options go all the
way from none, the low end (a single LED which changes color or goes out when
the charge is complete), or the high end, a mechanical meter (or LED analog
meter) that indicates charge current. Other options are a multi-LED bar
display, a three light display (power on, charging, and battery failure for
example), or whatever your industrial designer comes up with!
17. Temperature/operating
range: (Optional.) The larger the range, the higher the cost. No need to
have an operating range greater than the safe charging range of the batteries.
18. Humidity: (Optional.)
This is not a big concern except for high voltage chargers, and marine
applications.
19. Altitude (Optional.) If
you have airborne or mountain top requirements we will want to design the heat
management to your needs.
20. Shock and Vibration:
(Optional.) Our products are designed for long life under normal use. If there
is a severe shock requirement (mounted on a generator?) let us know.
21. Safety Requirements:
(Optional.) Most customers have some requirement for safety agency approval.
All products shipped to Europe need CE marking. We have a safety engineer on
staff who can help you decide which agencies are appropriate for your product.
An option is to have us design to safety and EMI standards without actually
registering with the agencies.
22. EMI Requirements:
(Optional) Electromagnetic compatibility standards may be a requirement
depending on market area and type of circuitry used. Any product containing a
microprocessor or a switching power supply comes under FCC regulations in the
USA. In Europe there is a susceptibility as well as emissions requirement. . In
both areas there are two classifications: A for heavy industry, and B
for residential, commercial and light industry. We can advise you on the
requirements, and can meet any standards as required.
23. Target Price: We can
make a charger for $1 or $10,000. I bought a flashlight that uses a charger
circuit consisting of a diode and a resistor. It takes up to 2 weeks to charge
it, but it is cheap! We want to match our technology to your customer's
expectations. Cost is affected by charger power, size, sophistication of the
charging algorithm, and cosmetics (case and display). For example lithium-ion
batteries require a smart charger to prevent explosions and maintain a long
battery life. Lead acid batteries are very robust and the charger can be cheap
if you don't care about getting the ultimate in battery life. If you can't give
us a target price, tell us what performance level (high, medium, low) you want
to see.
24. Equipment safety. Class
I--grounded, Class 2--double insulated, Class 3--Internal (battery or solar)
powered.
25. Operating Environment.
Indoor or Outdoor, mobile (moving land vehicle), marine, portable,
stationary, permanently connected, etc.? Each of these and other environmental
factors (altitude, humidity, etc.) have their own performance and cost
tradeoffs. These are a vital consideration for reliable operation. PowerStream
Products are designed for indoor use at altitudes up to 6000 ft (1828 m) unless
specified otherwise.
24. Other Thoughts: Who will
design the plastic molded case? Do you need a breadboard or brass board for
early testing? |
Fax:
801-764-9061