Faulty chargers causing costly failures
Winter & Smith were called in by a long-time customer facing a costly problem—faulty chargers failing in the field. These chargers, sourced from the Far East, were leading to expensive warranty claims and recalls, draining the laser tag company’s profits. In an industry where reliable technology is everything, there was no room for failure.
What did this project involve?
- Electronics Design of bespoke battery charger
- Embedded software design for Microchip PIC processor
- Electromechanical and PCB Assembly
- Mechanical design and CNC of front panels
- Rack wiring
A bespoke 8-battery charging system
We jumped into action, designing a custom-built 8-battery charging system from the ground up. This bespoke solution integrated multiple high-quality components to ensure durability, efficiency, and flawless performance.
Here’s how each key feature was incorporated into the custom 8-battery charging system:
Battery discharging & conditioning
To maximise battery lifespan and maintain peak performance, the system includes a discharging and conditioning cycle. This prevents memory effects and ensures each battery is properly prepared before recharging.
Voltage monitoring of batteries
Continuous real-time voltage monitoring allows the system to detect and respond to changes in battery status, ensuring each battery is charged optimally without the risk of over voltage.
Microprocessor-controlled system
A sophisticated microprocessor manages the entire charging process, adjusting power levels dynamically and protecting against overcharging, overheating, or voltage fluctuations.
Voltage monitoring of batteries
Continuous real-time voltage monitoring allows the system to detect and respond to changes in battery status, ensuring each battery is charged optimally without the risk of over voltage.
Initial fast charging
To minimise downtime, the charger begins with a rapid charge phase, quickly restoring most of the battery’s capacity while maintaining safety and efficiency.
Float charging for final cycle
After the initial charge, the system switches to a float charge mode, trickling in just enough power to top off the battery without overcharging. This ensures maximum charge retention and battery health.
UK/EU mains lead
Designed for versatility, the system includes a high-quality UK/EU mains lead, ensuring compatibility with different power supplies while maintaining safety and compliance with regional regulations.
Why system design tech with us?
We design bespoke systems that prioritise reliability, efficiency, and longevity. With expert engineering, high-quality components, and a focus on real-world performance, our solutions reduce failures, minimise costs, and ensure seamless operation. When precision matters, we deliver!
