By continuing browsing this website, you accept the use of cookies or other tracers for statistics of visits to optimize the functionality of the site. For more information and for tracers settings

Select language
  • Deutsch
  • Español
  • Français
  • 中文
  • 日本語

We energize the world

Contact us
Follow us
  • Home
  • About us
    • Who is Saft
      • Saft In Brief
      • Our Strategy
      • Our History
      • Saft Worldwide
      • Code of Conduct
    • Manufacturing our batteries
      • Battery Chemistries
      • Research & Development
      • Environmental Responsibility
      • Certifications
  • Market sectors
    • Aerospace & Defense
      • Aviation
      • Space
      • Defense
    • Buildings & Industries
      • Data Centers
      • Mining, Cement, Chemicals
    • Medical
      • Hospital Buildings
      • Medical Devices
    • Telecom & Networks
      • IoT
      • Metering
      • Security Systems
      • Telecom
    • Oil & Gas
    • Transportation
      • Industrial Vehicles
      • Marine
      • Rail
      • Racing
      • Transportation Infrastructure
    • Utilities
      • Power Generation
      • Transmission & Distribution
      • Renewables & Microgrids
      • Off-Grid
  • Products & solutions
    • Product Search
    • Training Courses
    • Services
  • Media & resources
    • Press Releases
    • Our Stories
    • Energizing IoT Blog
    • Customer Magazine
    • Events
    • Knowledge Hub
      • White Papers
      • Webinars
      • Technical Articles
  • Careers
    • Current Opportunities
    • Our People
    • Our Values
    • Our Company Culture
Home » Energizing IoT » How to best integrate batteries into your smart object

How to best integrate batteries into your smart object

Back to all articles
Share on
Empowerment - Isabelle Sourmey - Application Engineering Civil Electronics Division - October 28, 2020

As there is no « one cell fits all » solution, there isn’t any universal solution to connect a cell to a device. And that’s even truer when it comes to industrial applications. The way to connect the cell to your device depends on the size of the cell, the environmental conditions to which the device is going to be exposed, the need to replace the battery or not during the device’s life time, the volume to produce and whether it needs to be automatically or manually integrated on the printed circuit board (PCB), and of course, the cost of the equipment. It may seem trivial to some, but a wrong connection can result in inadequate, less effective devices.

In this article, we will give you some recommendations on how to choose the right connection; a solution that will last as long as your device is operating, without maintenance, thus helping you to maximize your end-users’ value and benefits.
 

The battery holder

The most popular system that we often find in consumer applications is the battery holder. Easy to use and generally inexpensive, it offers the advantage of letting the end user replace the cell easily. It isn’t however adapted to industrial applications for several reasons:

  • The risk of mixing different cell technologies or different cell state of charge is more important, especially if the replacement is being performed by an inexperienced user
  • The cell could be positioned the wrong way (inversion), which could lead to safety issues
  • The system is not adapted for long life applications as there is a risk of micro-corrosion of the terminals if the cleaning is not performed periodically or during replacement.
  • The system isn’t as sturdy as a rigid connections welded system or a wired connection. The battery holder could lead to a risk of micro-cut of voltage in case of shock or vibrations during transport or usage.

If this technology is adapted for consumer products using alkaline cells, it is not recommended for industrial applications using Saft products. For the latter, we recommend two different solutions.  
 

Rigid connections welded system

For industrial applications, especially if the equipment is being fitted on large volume assembly lines for mass production, we recommend the usage of rigid connections electrically welded on the cell and then soldered on a Printed circuit boards (PCB) on the other side. Different kinds of connections exist to allow this assembly with or without a polarizing slot:  

Battery connections

This technology is particularly well adapted for small size cells (AA & A). It offers a perfect electrical connection with a minimum connecting resistance. There is little chance of degradation during the device’s lifetime, it is economical, and it makes possible the automatic insertion of a cell on a PCB.

However, it creates a rigid link between the cell and the PCB, and the mechanical fixation of the cell creates constraints if the application is subject to shock and vibrations, which limits the usage of welded system for C and D size cells. The replacement isn’t easy either due to the welding.

The soldered connections also have to be very precise, especially for automated mass production. The dimensional tolerances of the cells, particularly at the level of the soldered connections can be slender, causing production line stoppages during assembly, or defective assemblies if the connections are not 100% precise. At Saft, we have created an automatic connection installation with a level of precision that is unmatched on the market in terms of process repeatability. The machine is used to laser weld 2 or 3 leg connections on the positive and negative poles of our 1/2 AA , AA and A size Li-SOCl2 cells, in a precise and repeatable way, ensuring rapid, reliable and cost effective integration of the cells in the final device.  
 

Wiring connection with or without connector system

For bigger size cells such as C, D, or for 1/2AA, AA & A (Flying Lead finish above) when they are replaceable, there is a third possible way to connect the battery to the device: via a wire with or without a connector.

The wire’s length and the connectors’ types, from standard to specific ones, will need to be tailored to the device, a service that Saft can provide to its customers.

This solution offers a very good electrical connection as there is a minimum connecting resistance; it is very flexible which allows for a good fixation of the cell in the application even if the latter is submitted to shock and vibrations. You can place the cell further away from the PCB, the solution doesn’t degrade over time and makes it easy to mechanically polarize the slots or replace the cells if a connector is included.

However, if there isn’t a connector, no automatic insertion will be possible. You’ll need a visual polarizing slot. Changing the cell might also prove to be difficult as welding becomes necessary. Finally, the solution might come at a higher cost as it is personalized.

 

Thinking about the battery early in the design process is recommended as your choice of battery and battery connections will greatly impact your product design and cost of total ownership (CTO). Choosing the right connection for your device requires taking into account the whole life of the battery, from cradle to grave: during design phase, industrialization, serial life (logistics support), after sales, and disposal of the battery. Again, our application engineers will gladly advise you on how to optimize your electronic design. Don’t hesitate to get in touch!

#Internet of Things #IoT #Battery #integration #Smart objects #how to
Share on

Newsletter

By signing up, you’ll be the first to hear about our news and receive exclusive advices.

We use your email address solely for sending our IoT newsletter. You can unsubscribe at any time using the unsubscribe button at the bottom of the newsletter.

For further information on how your data is managed, please consult our privacy policy.

Thank you for subscribing! A confirmation email has been sent to your mailbox.

Most popular items

  • Choosing the right battery for your IoT device and making the most of it: 20 resources you can’t miss.

    Céline Bernard - Inside Sales and Marketing - Connected Energy Division - 4 minute read
  • Smart water management: 5 innovative solutions to water scarcity offered by the IoT

    Céline Bernard - Inside sales and Marketing - Connected Energy Division at Saft - 4 minute read
  • From the sensor to the datacenter, providing reliable power to secure your data all along the IoT value chain

    François Danet, Global Business Development & Ricardo Nunes, Li-ion Product Manager | Data Center Power solutions & Services - 4 minute read

Not to be missed

Download the IoT Cheatsheet

TRENDING TWEETS

@Saft_batteries 🌞🔋🎓 What is the difference between #Power & #Energy? Here is the perfect visual to explain this last and particularly tricky question of our #SummerBatteryAcademy. Need more resources to master #battery basics? 👉https://bit.ly/Saft_technical_tools #batteries #saft
@Saft_batteries Under extreme weather conditions and on tough terrain, Saft #batteries contribute to protecting endangered #wildlife in the most isolated areas of the world! Find out more on how #IoT devices are being used to benefit vulnerable ecosystems Right pointing backhand index https://saftbatteries.com/energizing-iot/how-can-iot-help-us-solve-our-ecological-issues-episode-2-biodiversity
@Saft_batteries #DigitalTwins ♊️solutions such as @deutschetelekom #IoT Solution Optimizer can help in reducing the time to market and also creating less defective devices🚀. Miguel Rodriguez explains how 🔋 http://bit.ly/Saft_Blog_e09
Follow us on Twitter

Related Articles

  • Empowerment - April 1, 2022

    Choosing the right battery for your IoT device and making the most of it: 20 resources you can’t miss.

    How to best power your IoT device for a long lifetime and a better return on investment? Discover the list of our top 20 resources to help you get the most of your battery. #Saft #Battery #Lithium

    4 minute read

    See more
  • IoT applications - March 22, 2022

    Smart water management: 5 innovative solutions to water scarcity offered by the IoT

    Less waste, less consumption, and a better management of the water’s quality can improve the preservation of our planet’s resources. Find out how the Internet of Things can help. #Battery #Lithium #IoT

    4 minute read

    See more
  • All about batteries - March 16, 2022

    From Sensor to Space: how Saft batteries support Satellite IoT connectivity to ensure continuous communication everywhere on earth

    Follow us to discover how satellites are used for communication and how the IoT is benefitting from our space experience… #Space #Satellites #Rechargeable battery

    4 minute read

    See more
  • Our products - March 10, 2022

    From the sensor to the datacenter, providing reliable power to secure your data all along the IoT value chain

    Read how Saft is powering the IoT all along its value chain, making sure the data is effectively captured by sensors, then stored securely to be available whatever happens. #Data Centers #cloud #Hyperscaling

    4 minute read

    See more
  • Sustainability - February 10, 2022

    How can IoT help us solve our ecological issues? Agritech

    The Industrial Revolution was instrumental in the development of ecological issues. Can the current technological revolution —and IoT in particular— help us find some solutions? #Environment #Internet of Things #Innovation

    5 minute read

    See more
  • IoT applications - February 3, 2022

    In the eye of the storm – When IoT helps predict natural catastrophes

    Making weather forecasts right as rain: Discover how IoT can help predict the weather more accurately #Meteo #IoT #Internet of Things

    4 minute read

    See more
  • All about batteries - January 25, 2022

    Lithium-ion batteries in use: 5 more tips for a longer lifespan

    In this article, we focus on how to care you for your Lithium-ion battery while in use to extend their lifespan. #Rechargeable battery #Li-Ion battery #battery care

    5 minutes read

    See more
  • All about batteries - January 13, 2022

    Charging your lithium-ion batteries: 5 expert tips for a longer lifespan

    In this article, we explain how lithium-ion batteries work and share our 5 top tips on how to charge your industrial-grade lithium-ion batteries to optimize their lifespan. #Rechargeable battery #Li-Ion battery #battery care

    3 minute read

    See more
  • IoT market & trends - December 15, 2021

    6 exciting IoT power optimization trends to watch out for in 2022

    We have gathered some of the main power optimization trends that are getting us all excited in 2022: 5G, DevOps, harvesting technologies and more! #IoT #InternetofThings #batteries

    3 minute read

    See more
  • IoT applications - December 8, 2021

    Powering the Industrial Internet of Things (IIoT)

    The Industrial Internet of Things (IIoT) has transformed the way industries operate. Batteries have been an integral part of this development. Find out how... #Battery #IoT #Industrial Internet of Things

    6 minute read

    See more
  • All about batteries - November 30, 2021

    The impact of the temperature on your IoT application’s power consumption

    Did you know that temperature is the main factor impacting your battery’s power consumption? A slight change can affect your battery’s capacity and service life. Find out why. #Battery #IoT #Internet of Things

    4 minute read

    See more
  • All about batteries - November 24, 2021

    Custom pack-making: designing your IoT batteries to the best standards

    Selection of batteries: check! But how to best integrate them in your IoT device? Here are the keys to successful custom battery pack-making. #Saft #Battery #battery pack assembly

    4 minute read

    See more
Copyright © Saft2022
  • Terms & Conditions
  • Privacy Policy
  • Site Map
  • Saft4U
  • Stock Check (North America only)
FOLLOW US