Electronic components are crucial in medical devices, enabling accurate detection, diagnosis, and treatment of medical conditions. Selecting precise and reliable components is essential for ensuring optimal performance in medical applications.

Pressure Sensors for Medical Applications

Merit Sensor LP Series - Surface mountable pressure sensors

Monitoring and controlling the amount of air, or positive airway pressure, into a patient’s lungs is critical for respiratory support. What you get with the LP Series is a sensor for very low pressures that is easy to solder to a PC board and connect to standard tubing. It is available fully compensated, saving you calibration time and equipment on the assembly line. It is also available uncompensated for lower cost. Once in the application, the LP Series performs with excellent linearity, hysteresis, and stability.

Typical Applications:

• CPAP
• Spirometers
• Ventilators
• Nebulizers

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Merit Sensor BP Series - Blood-pressure transducers

Our BP Series blood pressure sensors enable continuous, reliable patient monitoring. Ideal for high-volume, low-cost applications, these AAMI-compliant sensors are customizable for other medical-grade applications.

Typical Applications:

• Invasive & disposable blood-pressure measurement
• ECMO machines
• Heart/lung machines
• Dialysis machines
• Infusion pumps
• Surgical procedures

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Merit Sensor MSS100 Series - Fully compensated pressure transducer

The MSS100 pressure transducer is perfect for medical, pharmaceutical, and bio-processing applications, such as blood analysis and gas chromatography. It is designed to withstand harsh liquids and vapors, providing durability and reliability. It features simple electrical connections via Molex connector and pressure connections via Luer fitting.

Typical Applications:

• Blood Analysis
• Gas Chromatography

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Magnetic Sensors for Medical Applications

Coto Redrock TMR (Tunnel Magnetoresistance) sensors are currently the most efficient magnetic sensors available, with the lowest power consumption, highest sensitivity, and smallest packaging. These sensors are ideal for a wide range of applications, including monitoring fluid flow, liquid level, proximity, anti-tampering, and enabling “wake-up” features. As next-generation measurement and detection devices demand smaller, more sensitive, and lower power consumption sensors, Coto Redrock TMR sensors are the perfect solution for battery operated devices.

Medical Level sensing

Coto RedRock TMR (Tunnel Magnetoresistance) sensors are highly sensitive and accurate magnetic sensors, making them ideal for use in medical leveling devices. These sensors excel in precision measurement, detecting minute changes in magnetic fields to provide accurate position or orientation data, which is crucial for diagnostic equipment and patient positioning. Their non-contact measurement capability is advantageous in sterile environments, eliminating contamination risks and ensuring hygienic operation. The compact size of TMR sensors facilitates their integration into small, portable medical devices, allowing for versatile use in various medical settings, from operating rooms to patient bedsides.

Additionally, the low power consumption of TMR sensors makes them suitable for battery-operated medical devices, ensuring long battery life for portable equipment. The stability and reliability of these sensors guarantee consistent performance, which is essential for patient safety and effective medical interventions. Furthermore, TMR sensors can be seamlessly integrated with other electronic systems and software used in medical devices, enabling real-time monitoring and adjustment of levels for optimal equipment performance. These attributes—precision, non-contact capability, compactness, low power usage, stability, reliability, and integration ease—make Coto RedRock TMR sensors perfect for accurate leveling in a wide range of medical applications.

Ingestible and Implantable Devices

Ingestible and implantable devices require efficient and reliable activation methods without compromising their protective encasement. Coto Redrock TMR sensors provide a contactless activation solution, ideal for these devices. For example, capsule endoscopes can remain in standby mode for up to 18 months and are activated when needed without depleting battery life prematurely. These sensors are crucial for ensuring the devices function correctly and maintain their integrity throughout their lifecycle, enhancing patient safety and device reliability.

Hearing Aids

Magnetic sensors in hearing aids facilitate mode switching, diagnostic checks, and response tuning. As demand for smaller, more discreet hearing aids grows, these sensors play a critical role.

Insulin Pumps

Continuous-feed insulin pumps rely on magnetic sensors to detect reservoir status, ensuring seamless insulin management and avoiding complications.

Caddock Precision Resistors for Medical Applications

Caddock’s wide range of resistors, including Type MP, MV, MS, TF, USF, MK, TK, T912, T914, T1794, MG, and TG, are used in various medical applications due to their exceptional performance and reliability.

MP, MV, and MS Series Resistors

These resistors are ideal for RF power circuits, providing high accuracy and stability in demanding applications.

Typical Applications:

• RF surgical equipment
• Endoscopy equipment
• Therapeutic devices

TF, USF, MK, TK, T912, T914, and T1794 Series Resistors

Used in measurement, data acquisition, and signal amplification circuits, these resistors ensure accurate patient monitoring.

Typical Applications:

• MRI equipment
• CT scanning equipment
• Medical laboratory equipment

MP Series Resistors

These resistors serve as heaters in laboratory analysis and fluid handling equipment

Typical Applications:

• Laboratory analysis equipment
• Blood and fluid handling equipment

MG and TG Series Precision High Voltage Resistors

Used in high voltage stability and accuracy applications.

Typical Applications:

• X-ray devices
• Defibrillation devices
• Therapeutic devices

MP, SR, and CC Series Resistors

These resistors are essential for reliable motor control and accurate positioning in various medical devices.

Typical Applications:

• Patient beds
• Operating tables
• MRI equipment
• Wheelchairs, scooters, and other medical devices

Precision Capacitors for Medical Applications

SRT Microceramique Non-Magnetic NP0/X7R Capacitor Series

Non-magnetic capacitors are vital in medical applications requiring precise electrical activity measurement or stimulation. These capacitors ensure a stable power supply, precise energy delivery, and contribute to the longevity and reliability of medical devices.

Typical Applications:

• Medical simulators
• Magnetic resonance imaging
• Medical test equipment
• Laboratory analysis systems
• Implantable devices

Rhopoint Components offer high-precision Electronic Components and Sensors essential for the medical industry, including pressure sensors, magnetic sensors, resistors, and capacitors. These components ensure accurate detection, diagnosis, and treatment in medical applications.

If you have any projects related to these components, our friendly and knowledgeable engineers are here to help. Reach out to Rhopoint Components to discuss your specific requirements and find the perfect solutions for your medical device needs.

The post What Electronic Components or Sensors can I use in Medical Devices? appeared first on Rhopoint Components.

The Basics

Basics of busbar shunt current measurement

Current measurement across a measuring resistor works by measuring the voltage drop directly across the resistor: 
Source Voltage (U) = Resistance (R) x Current (I) + Thermoelectric Voltage (Uth) + Induced Voltage (Uind) + Voltage drop across leads (Uiext).

The analog measurement signal is amplified, then converted into a digital signal and provided to the evaluation electronics. In this case, fault voltages not caused by a current flow (e.g., due to influences of the material or the design) can falsify the measurement result – especially in the case of low-ohmic shunts where the voltage drop is very small. Also to be considered is the power dissipation, which cannot be neglected at very high currents.

Isabellenhütte’s resistance materials are physically optimized in such a way that disruptive influences are kept to a minimum from the outset. The matching design and optimized PCB layout also improve the measurement performance of the resistor. Due to the low-ohmic values of the shunts, the power loss and thus the heating in the component can also be kept low. In addition, the components maintain the specified tolerances in the complete temperature range, at full load and over the entire life cycle.

Long-term stability

Long-term stability is an important parameter with regard to the quality of a current sensor, which is evaluated as a function of the operating temperature. Isabellenhütte’s busbar shunts are characterized by very good long-term stability. The temperature-related drifts are only slight, even in continuous use. To achieve this, the resistance materials must be stable against corrosion and not undergo any metallurgically induced changes of state. During production, the resistance alloys undergo a temperature stabilization process that optimizes the long-term properties of the components. Stability values in the ppm range per year are possible with these alloys.

Temperature dependence

When considering the temperature dependence of resistors, the temperature coefficient TCR plays an important role. This coefficient indicates how much the resistance value changes over a given temperature range and is measured in ppm/degree of heating (in Kelvin). The smaller this change due to heating, the better it is for the application.

There are other factors that can affect the temperature coefficient, such as the contacting capabilities. If the connection is not made properly, the temperature coefficient of the resistor may be distorted due to the influence of the measuring line or contacting.
The Isabellenhütte busbar shunts already have a very good TCR value. Optimized positio¬ning of the contacting options, as recommended by Isabellenhütte, can further improve the TCR value. This reduces the measurement error in the overall system; the user receives the best possible measurement result.

Load capacity

The busbar shunt manufacturing process has an extremely positive influence on the load capacity of the busbar shunts. Due to their special structure, the heat generated in the resistor material is efficiently dissipated through the welded copper terminal, which has high thermal conductivity and heat capacity. Due to their high electrical conductivity, the solid copper terminals in turn ensure uniform current density and heat distribution in the resistor. This results in a low internal heat resistance.

Due to these properties, the resistors can withstand a high load at full power up to very high terminal temperatures – the derating point of the so-called power derating curve is therefore high. This manufacturing process avoids hotspots and achieves a high pulse and continuous load capacity.

The Standard Busbar Shunts

Standard busbar shunts

The standard busbar shunts are components for high current applications that do not have a contacting option of the kind integrated in the analog sensors. In this case, the voltage taps must be connected by the customer. The busbar shunts are used in 12 V, 24 V and 48 V applications as well as in high voltage applications at > 400 V. They form the basis fora current measurement in the Battery Junction Box (BJB), alternatively also called the Battery Disconnection Unit (BDU), and are produced using electron beam welding technology.

They consist of two copper strips that are electron-beam-welded together with a resistance alloy (with a high copper content) to form a composite material. Thanks to this technology, they offer a high degree of flexibility, as the composite material can be adapted to a wide range of shapes and applications in terms of stamping and bending. Isabellenhütte’s various resistor series comply with the RoHS directives and are qualified in accordance with the high requirements of the AEC-Q200 standard for the automotive sector.

Isabellenhütte BAS Series

The BAS is the basic version of the busbar shunts for current measurement of battery currents. Possible applications include all types of hybrid and electric vehicles such as cars, trucks, forklifts or industrial trucks. Other potential applications include current measure-ment in welding equipment or in stationary or mobile energy storage systems. The trend with regard to the use of busbar shunts is clearly moving towards ever lower resistance values. The higher currents that must now be measured in the e-mobility sector are also accompanied by higher power dissipation, so developers want to keep this to a minimum by using resistors with the lowest possible resistance values.
 
The BAS is available with resistance values of 35, 50, 100, 200 and 500 μOhm. Depending on customer requirements, there are now around 30 standard variants of the BAS: with two or four holes, with different hole diameters, without holes, in different lengths, in tinned and untinned variants. On the one hand, tin plating can protect the base material of the bus bar, copper, from corrosion. On the other hand, the tin plating achieves a very low contact resistance, which inevitably occurs between the shunt and the bus bar when they are screwed together. With tin as the surface material, this contact resistance is somewhat lower thanks to the soft nature of tin.

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Datasheet

Isabellenhütte BAL Series

The BAL is the smallest busbar shunt in Isabellenhütte’s portfolio. It is ideal for 12 V battery management systems in all vehicles. In addition, it is potentially of interest to customers looking for a standard solution for the conceptual design of an energy storage system. Power losses of up to 12 W and a continuous current of 350 A with an R-value of 100 μOhm are no problem for the BAL. In the untinned version, the shunt offers the possibility for integration in a bus bar via laser welding, while the tinned version helps to reduce the contact resistance via a classic screw connection on a bus bar.

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Datasheet

Isabellenhütte BAN Series

The standard busbar shunts also include the BAN. With a size of 84 x 36 x 3 mm (L x W x D) and a low resistance value of 25 μOhm, the BAN is ideal for monitoring very high currents above 1,000 A, especially for high voltage BMS applications in PHEVs and BEVs. The BAN is also available as a TCR-optimized version, making it ideal for highly integrated solutions with very high accuracy. In addition, the shunt is available with two or four mounting holes for screwing onto the bus bar.

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Datasheet

Isabellenhütte BAX Series

The BAX is currently the most powerful busbar shunt with the largest cross-section in the standard portfolio (84 x 36 x 4 mm, L x W x D). It was developed specifically for high-voltage batteries in electric vehicles. It is designed for currents of over 1,000 A. Hybrid vehicles use smaller electric motors with 48-volt systems, while pure electric vehicles are high-voltage applications with voltages from 400 to 800 V or higher.
 
In this respect, the performance requirements for the component are also extremely demanding. It must be able to handle a continuous high current, in some applications 500 to 1,000 A – permanently.
 
Such extreme power loads require resistors with a larger construction and lower resistance values to keep power losses to an absolute minimum. In addition, the BAX must also be able to withstand fault conditions such as short circuits when 2,000 or 5,000 A occur in a few milliseconds. In these high-current applications, the long-term stability of the busbar shunt is also crucial, as this has a direct influence on the residual range indicator in the vehicle. The more accurately the current can be measured over a long period of time, even at different temperatures, the more accurate the indication of the remaining range will be. The BAX meets the high requirements for fault tolerance over the life cycle of the component. The extremely low-ohmic BAX shunt is currently available in two variants; one with a resistance value of 20 μOhm, the other with a corresponding value of 5 μOhm.

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Datasheet

Analog Sensors

Higher integrated shunt solutions

Higher integrated shunts are solutions that not only consist of the shunts themselves, but also include voltage taps and contacts, which are provided on the shunts in various forms for the customer. Various solutions are available on the market.

Analog sensors with PCB

The analog sensor with PCB is a busbar shunt that can either be developed on a customer-specific basis or selected from Isabellenhütte’s standard product range. In addition, it contains a soldered-on printed circuit board (PCB), via which, among other things, direct tapping of the measurement signals is possible. Furthermore, depending on the configura¬tion, the temperature can be measured via NTCs (Negative Temperature Coefficient Thermistors) on the PCB and the resulting values can be used to compensate for the temperature coefficient.

Depending on the configuration, the analog sensor thus fulfills two of the main functions of a battery management system: current measurement (CSM) and temperature measure¬ment (TMP).

On the one hand, this ensures reliable transmission of measurement signals and also eliminates an additional process step. A connector is used to tap the voltage and tempera¬ture values and transmits the analog signal to the customer’s higher-level system.

The advantage for the user: The user gets a very good measurement signal because the PCB is placed exactly where the temperature coefficient is most favorable. If the user chooses his own contacting, this could be at a point where the TCR cannot be measured optimally, so that the measurement result is negatively influenced. On the other hand, with the PCB applied directly to the edge of the resistance material, the best possible pickup of the measurement signal is guaranteed.

The analog sensor with PCB also promises greater flexibility in terms of installation space: The system does not need to be designed in a special way so that the shunt and separate PCB are as close to each other as possible. It should be noted that the lead to the higher-level PCB can act like an antenna and thus interference can be received. However, this problem can be solved with a twisted or shielded lead.

Further variants – with different resistance values and shunt dimensions, and with ISO26262 qualification and more – are currently in the development phase and can be requested.

Another plus: On request, Isabellenhütte can laser the actual R-value of each manufactured component, including the temperature coefficient curve, onto the shunt in the form of a DMC code. The customer thus receives a “quasi-plug-and-play” solution and can use it immediately in the target system.

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Datasheet

Analog sensors with press-fit pins

An alternative to connecting the shunt via a PCB with connector is to subsequently attach a PCB (developed by the customer) via a press-fit connection.

In this area, Isabellenhütte has responded to market requirements by providing another contacting option with press-fit connections, which allows the customer’s main PCB for the application to be directly contacted with the shunt via the press-fit pins. The attach¬ment of the press-fit pins offers some flexibility in terms of the position and number. In the areas of the press-fit pins, the busbar shunt must be uncoated, whereas coating is possible at the connection points to the bus bar in order to reduce the contact resistance.

The press-fit pins are conventional press-fit connections in accordance with IEC 60352-5. Isabellenhütte offers three different standard heights for these pins, although custom heights and other pin variations are also possible.

Three BAS shunts with R-values of 35, 50 and 100 μOhm and two press-fit pins each are available as standard. Customized designs can be easily implemented.

The advantages of this press-fit technology include the ability to quickly create connections without soldering. In addition, the distance of the PCB from the shunt provides protection in case of excessive temperatures at the shunt, which could possibly damage the PCB. Furthermore, at high currents, the distance between the PCB and the shunt can also reduce the influence of the magnetic fields on the semiconductors located on the PCB, which are sensitive in some areas.

Other contacting solutions

Contacting a busbar shunt with a PCB or press-fit pins covers nearly 80 – 90% of the total busbar shunt market. In addition to these two solutions, another contacting option should be briefly mentioned: a flex lead applied to the shunt, the bonding of wires to the shunt, THT (through-hole technology) construction. The remaining solutions, such as flex lead or wire bonding, also play only a minor role for cost and technology reasons. The THT design is mostly used in industry, but less so in the automotive industry.

Conclusion: High flexibility in contacting

The key point of the BAx series, apart from its suitability for high-current applications – from electric vehicles to welding equipment – is the flexibility in terms of contacting to the customer’s measuring system. Depending on installation space, size and measurement requirements, users can choose from numerous options: according to resistance values, tinned/untinned design, with integrated printed circuit board, soldered pins or from individual solutions such as flex cables or metal injection moulding.

In the consultation, it is important for Isabellenhütte to show that the good properties of the busbar shunts can only be used optimally if the customer-side connection within the application is also considered. The contacting of the current sensor is part of the best possible measurement result. A wide variety of influencing variables must be taken into account in advance. Isabellenhütte will be happy to advise you on the development of a viable measurement solution that takes all influencing factors into account.

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IVT-Series as a Link between Generation and Consumption

Home/commercial/industrial storage is the answer to the feeding of decentralized generated electric energy into the power distribution network. The rising state-subsidized expansion of renewable energies is increasingly leading to unstable situations in the distribution network. The charm of the self-sufficient energy supply is what is attractive about the home storage applications up to a few kW of power. The avoidance of peak power consumption, however, is what is attractive about commercially or industrially operated large storage applications up to a few MW of power. In UPS systems, however, an environmentally independent energy generation is usually relied on, such as CHP or a diesel generator. All stationary electric energy storage units combine the need to measure current and voltage precisely.

ICD Series combats high cost pressure with home storage applications

The home storage applications in the B2C market are under extreme cost pressure. However, the demand for an accurate and particularly high-resolution current measurement of the charging and discharging currents still exists. With the ICD Series, a concept has been developed that exclusively focuses on a digital and calibrated current measurement as well as an ampere-hour metering. Due to the low system voltage, a galvanic isolation can be done away with and the ICD SERIES can meet the relatively low nominal currents under 100 A with a very compact design and resolution of 1 mA.

IVT Series Daisy-Chain Functionality for Large Commercial/Industrial Storage Units

With large electrical energy storage units, several stacks of very high power are connected depending on the application case. Each stack has its own BMS. The system voltages of these stacks are now between 800 and 1,000 V due to the lithium-ion technology. The IVT Series can be used permanently in these systems without any problems due to its galvanic isolation up to 1 kV. The precise and high-resolution measurement of the charging and discharging currents in the individual stacks as well as the option to use the voltage measurement channels to measure the stack voltage is a clear advantage of this highly integrated solution. Another advantage in the system integration of the IVT SERIES is the ability to loop the supply voltage and the CAN bus. The sensors can thus easily be connected in a type of daisy chain from stack to stack and be addressed via configured CAN IDs.

IVT Series Supports Supply Security in UPS Systems

A battery-powered uninterruptible power supply unit (UPS) has many application areas, such as server centers, hospitals, mobile communications antennas or generally for power supply in regions with a weak network infrastructure. In contrast to home/commercial/industrial storage units, the lead-acid battery is still widely used here as battery technology. If the energy feed can be influenced by means of a CHP or simple diesel generator, then the battery diagnostics of lead-acid batteries become more important. With lead-acid batteries, the IVT-Series is proven above all by the additional voltage measurement channels in addition to the precise and high-resolution current measurement. Thus, the center tap of the 48 V lead-acid system in particular is measured in addition to the total stack voltage. This facilitates the service and monitoring of the individual cell blocks during maintenance and repair. The performance always depends on the weakest cell block, especially with lead-acid applications.

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IVT-S Supports BMS for Lithium-Ion Traction Battery Systems

An electric drive for vehicle applications consists in principle of the following components: electrical converter, HV box / power distribution unit consisting of pre-charge circuit, fuse, protection in the negative and positive pole of the battery as well as the traction battery or mobile electric energy storage unit, including the battery management system (BMS).

High Quality of the Battery Diagnostics Parameters of the BMS due to the IVT-Series
 

The battery management system of a traction battery has two main functions. On the one hand, the active or passive balancing of the individual lithium-ion cells.

On the other hand, the calculation of the battery diagnostics parameters of the traction batteries state of charge, state of health and state of function. Determining the state of charge requires a particularly precise and high-resolution total current measurement, which is transmitted by the IVT-Series to the BMS via CAN bus.

The resolution in the mA range also allows for the detection of the standby currents, also referred to as leakage currents.

Highly Integrated Sensor with Additional Functionalities

 

Due to the additional voltage measurement, the IVT-Series also allows for the monitoring of the total battery voltage, the pre-charging circuit, the circuit breaker and the fuse.

The highly integrated sensors not only capture the raw data for current, voltage and temperature measurement, but also determine the power, energy and ampere-hour values on the software side as integrated values and transmit these directly to the BMS via CAN bus.

Our customers thus receive a dynamic, stable, calibrated and compact current and voltage measurement system that also offers real advantages in terms of the total system costs.

Galvanic Isolation up to 1,000 VDC Permanent

 

The development of higher energy densities in lithium-ion technology is leading to ever-increasing system voltages, which is why the IVT-Series provides a permanent galvanic isolation of 1,000 V DC.

Isabellenhütte. “Electromobility.” Accessed May 16, 2024. https://www.isabellenhuette.de/en/precision-measurement/applications/electromobility.

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Options and Considerations to Extend Battery Life

Battery-operated, wirelessly-connected devices are becoming increasingly pervasive in today’s society.  Driven forward by advancements in wireless and battery technologies, coupled with shrinking electronic components that consume less power, and cloud-based services ready to collect, analyze and disseminate data, these devices are commonly found in consumer, medical and wearable devices as well as in commercial, and industrial applications.

Whether the device is a wearable continuous glucose monitor (CGM), an ingestible or implantable medical device, or a smart home device, asset tracker or environmental monitor, all share the common requirement of small size, long life, reliability and ease of use. One of the major problems faced by designers of these products is powering on the device when needed.

Powering on an IoT device only when it is needed (or keeping it powered down before it is deployed) is vitally important because designers want to use the smallest, lowest cost battery possible.  For this reason, extending battery life is always a design goal; battery drain must be minimized during use as well as before it has been powered on.

One popular example is the continuous glucose monitor (CGM) prescribed to a Type 1 or Type 2 diabetic. This device adheres to a patient’s body, continuously monitoring his/her glucose level.  Resulting data is wirelessly transmitted to the patient, doctor and/or insulin pump.  CGM’s must be very small, “water proof”, easy to attach and have a reasonably long life before they run out of battery power. 

There are three basic options for powering on these devices at the point of use or deployment. For each of these options, essential variables for consideration are battery current drain, size, ingress protection and user friendliness.

The first “Power ON” option is electromechanical or the common “switch.” This option is the means for powering on most battery-operated electronic devices such as laptops and phones. Although switches come in many forms, (e.g.; push button, slider or toggle) they operate on the same principle of opening and closing a mechanical contact to allow current to flow (when closed) or completely prevent it from flowing (when open).  With regard to the first consideration of current drain, the electromechanical switch is highly efficient because it is a passive device which consumes no power.  However, in terms of size, mechanical switches are a poor option, especially given the size constraints of many wearable, ingestible and implantable medical devices and other small IoT devices. In terms of ingress protection, (or need to have a device that is impermeable to water and humidity) mechanical switches are not the best option as designing a switch that can be mechanically moved by the user into on/off positions while maintaining impermeability is challenging. Lastly, the consideration of user friendliness, or ease of use, rates poorly with mechanical switches for two reasons – first: since the user must actually take this step (and many need to be instructed to do so), the requirement for many devices is “out-of-the-box  turn-on” –  a clear conflict with manually operated switches. Secondly, a very small mechanical switch, necessitated by a very small device, could pose a problem for users’ ability to actually move the switch to the ON position, thereby reducing usability. So, in summary, mechanical switches score highly in terms of current consumption but very low relative to ingress protection, size and ease of use.

Wireless power on is the second option to analyze. Because the devices already have wireless capabilities to transmit data, designers could technically use that same wireless capability to power on a device from a mobile phone app. From an ingress protection standpoint, powering on wirelessly is rated very highly. And, from a size standpoint, powering on wirelessly also rates highly as there is nothing more to add to the device for this functionality. However, from a current drain standpoint, wireless power on scores extremely low because a wireless receiver inside the device must be powered on to receive a signal to power on. For this reason alone, wireless power on is rarely used for devices that have stringent battery life requirements.

The third option is the use of a magnetic sensor inside the device to initiate the power on function. In this case, a magnetic field is applied to the sensor to trigger the power on.  The magnetic field is typically produced by a magnet that is located within the product’s packaging or in an auxiliary component to the device (such as an applicator for a CGM). The magnetic field can also be applied by the user swiping across the device with a hand held magnet. Magnetic sensing scores very highly for ingress protection (because it is a “contact-less” method).

Magnetic sensing also scores very highly in ease of use – especially when the magnet can be embedded in the device packaging (enabling “out-of-the-box power on”) or in an auxiliary component to the device (e.g.; an applicator). Sometimes the device, itself, is designed as two components that must be connected together at the time of deployment.  In terms of current drain and size, the desirability of magnetic sensing depends entirely on the magnetic sensing technology.  Older, more traditional magnetic sensing technologies types were either small in size, but high in power consumption (Hall Effect) or large in size with zero power consumption (reed switches).  However, many new devices are designed with a newer magnetic sensing technology called Tunneling Magnetoresistive (TMR) which offers both very small size (as small as an LGA-4) and extremely low power consumption, similar to the reed switch. In effect, TMR magnetic sensors offer the “best of both worlds.”

With the current onslaught of new devices designed to make life easier, safer, contact-less and/or operable remotely, electronic designers are having to adopt new technologies to keep up with the evolving requirements of battery-operated wearables, implantables, ingestibles and other IoT devices.  In terms of best capabilities relative to small size, lower power consumption, ingress protection and ease of use, magnetic sensors – and TMR sensor technology in particular – are helping to make “impossible” designs possible.

For further information, including advice on battery types not included in this report, please contact one of our engineers today!

Caption (for above picture): The TMR Magnetic Sensor offers almost zero power consumption in an ultra-miniature package size; and its contactless “power on” capability promotes ease of use.

 

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ABOUT THE COMPANY

Established in 1917, Coto Technology (www.cotorelay.com) is a worldwide market leader in the design and manufacture of advanced, high-reliability switching and magnetic sensing solutions sold into the Medical, Automotive, Data Acquisition, Instrumentation, Process Control, Telecommunications, Automatic Test Equipment and Security markets.  RedRock® is a registered brand of Coto Technology’s Sensor Product line.

The post How to power on a battery operated medical or IoT device appeared first on Rhopoint Components.

Merit Sensor

Process Connections & Fittings

The process connections or fittings of a pressure sensor is a critical component that can be customised to ensure seamless integration into various systems. By adapting the connection we are able to find allows for a perfect fit with the customer’s existing setup or find a best match for the location or environment that the sensor is to be used . This enables the sensors to be easily installed in a wide range of applications such as Aerospace, Downhole. Oil & Gas and Subsea, enhancing functionality and reliability. Our manufacturers offer various connections including Male NPT connectors, UNF, Autoclave, E3, E4, Double o-ring, Differential o-ring, Weldable tube, Internal pipe and Adapters.

Output Signal

Customisation of the output signal is another bespoke option offered by our manufacturers. This modification enables the pressure sensors to communicate effectively with the customer’s equipment, ensuring that data transmission is both smooth and efficient. Whether the requirement is for analogue or digital signals, adjustments can be made to meet the specific communication protocols of the application, facilitating accurate data interpretation. Selecting the appropriate output signal depends on a few pieces of information regarding the application. Is this an existing setup where the output signal is already defined? What is the supply voltage available to power the sensor? How far do you need to transmit the output signal of the sensor? All of these application questions will help guide us to the most appropriate output signal. Some of the options we can offer are:

• 4-20mA
• Voltage output signals (0-5V, 0-10V, 1-5V, 1-6V, 1-10V, 0.5-4.5V ratiometric, 0.5-2.5V non-ratiometric, etc.)
• Millivolt output signals (10mV/V, mV uncompensated, etc.)
• Digital: RS-232, RS-485, CANopen or SPI. Direct interface/connection to a host.

Pressure Range

Adjusting the pressure range of the sensors allows for accurate and reliable measurements across diverse operating conditions. This customisation ensures that the sensors can perform optimally within the specific parameters of the customer’s application, whether it involves low-pressure environments or high-pressure systems. By offering this flexibility, we can ensure that the sensors provide precise readings, critical for maintaining operational integrity and safety.

Electrical Interface

The electrical interface can also be customised to enhance compatibility with a broad array of devices and ensure the suitability of the connection for the application environment. This tailor-made approach ensures that the sensors can be effortlessly connected to the customer’s equipment, promoting ease of use and integration. Our manufacturers offers a variety of electrical terminations to fit just about any installation. Customers can expect connectors such as:

• Standard Cables
• High temperature Cables
• Solder Hooks (pig-tails)
• DIN 43650-A and C
• M12x1
• Packard Metripack 150
• 6-Pin Bendix
• Deutsch DT04 3 Pin and 4 Pin
• Hermetically sealed connectors

Certain product families have a limited selection of options due to hazardous certifications and design limitations.

Wetted Materials

One of the most important steps when specifying the appropriate sensor for your application is selecting the wetted material of the process connection (or pressure port). Understanding the operational location, temperatures, mounting and proximity to other devices is important. Selecting the proper material, connections and external surfaces of the sensor will help ensure reliable, long term operation.

Consideration of the media (fluid or gas) and temperature that will be measured is vital. The outside surface material (including inside the pressure port), or “wetted material” must be taken into consideration during the selection or design. If the wetted material is not compatible with the environment media being measured, your sensor will degrade over time. Please speak to one of out engineers to discuss the best material for your application.

Our manufacturers are able to offer the below materials on selects sensors:

• 17-4PH Stainless Steel (UNS S17400)
• 316L Stainless Steel (UNS S31603)
• Inconel 718 (UNS N07718)
• Inconel 725 (UNS N07725)
• Hastelloy* C276 (UNS N10276)
• Titanium BT9 (Grade 12)

*Hastelloy® is a registered trademark of Haynes International, Inc.

When creating a custom pressure sensors, each customisation option undergoes a thorough review on a case-by-case basis to assess feasibility and ensure that it meets the specific needs of the application. Rhopoint Components Ltd and our manufacturing partners are dedicated to providing support and expertise throughout the customisation process, ensuring that each sensor is perfectly adapted to deliver optimal performance and reliability.

Contact our engineering team for expert guidance and to explore our customisation options. 01342 330470 | sales@rhopointcomponents.com

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1-5V, 1-6V, 0-5V, 0-10V, 0.5-4.5V, 0.5-2.5V

3-Wire Voltage Wiring Schematic

How To Guide

For this how to guide, we have three components; power supply, Core Sensors pressure transducer, and a meter or other DAQ system.

1) Power Supply – Connect the positive (+) terminal of the power supply to the +V pin or wire of the transducer. Connect the negative (-) terminal of the power supply to both the Ground (GND) pin or wire of the transducer and the Common (COM) terminal of the meter or DAQ. If using a bench test setup, this is commonly done by using a male to male banana plug to connect the power supply and meter and stacking a banana to alligator clip to connect the power supply to the transducer.

2) Meter or other data acquisition (DAQ) –  Connect the Volts input terminal of the meter or DAQ to the Signal pin or wire of the transducer.

* In certain circumstances, there may be an additional pin or wire used as a case ground. This connection is not critical to the output signal but may be critical to maintain listed certifications of the transducer. Please refer to Core Sensors wiring guides to verify wiring prior to installation.

Common Applications

Tank Level Monitoring – For tank level applications, a voltage output pressure sensor with an IP-68 rating can be packaged with a SCADA system to remotely monitor fuel or water level for remote installations requiring low current consumption due to battery life concerns. The CS12 Submersible Pressure Transducer and CS82 Intrinsically Safe Submersible Pressure Transducers can be manufactured with a low current consumption ASIC to perform in this application.

Oil Field Equipment – In remote oilfields, voltage output pressure sensors and temperature sensors consume less battery life while providing enough signal to measure the media and transmit the signal to the telemetry unit. Data is then sent to the cloud for analysis and monitoring.

IIoT – Industrial applications continue to take advantage of IoT technology. Factories are measuring pressure and temperatures of test equipment as well as automation equipment to maximize efficiency, especially in locations where it is too costly or difficult to run power.

HVAC and Refrigeration – Voltage output signals continue to be a popular option amongst HVAC/R OEM and service installations. Due to the low cost and ease of use, pressure, temperature, and combination sensors can all be quickly integrated with noise immunity within the commonly short distances where sensors are run in HVAC automation applications, such as boiler rooms. Products such as the CS10 Industrial Pressure Transducer can be designed with a voltage output signal for low to high volume applications.

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The millivolt output signal is the oldest signal, yet still has popular uses today. Sensors with millivolt output can be roughly separated into two categories; compensated and uncompensated. Compensated sensors are generally ones where the output has been trimmed with resistors to have a set zero and span tolerance, along with a specific sensitivity (commonly 5 or 10mV/V) over a specified temperature range such as 0-55°C. Uncompensated millivolt output is generally the raw output of the sensor that has not been adjusted or trimmed, and is usually stated with a typical output range, such as 100mV output, +/-25mV @ 10VDC excitation. With either choice, one common advantage of millivolt output is the response time to changes in pressure. The frequency response time of millivolt output sensors is fast because there are no circuits to slow down the signal changes.

Choosing compensated vs uncompensated depends on the needs of the application. If the application includes a signal conditioner that simply amplifies the sensor output, compensated is usually the better choice because the sensor is already set to meet published performance over a specified temperature range. If the application is one where the equipment will be characterized and compensated/error corrected as a whole using a signal conditioner that can set zero, span, and temperature compensation, an uncompensated output is a good choice because it maximizes that output available for adjustments and error correction.

In physical terms, one of the primary advantages of millivolt output sensors is size and packaging flexibility. Because there are no ICs and other large electronic chips to fit inside the sensor housing, millivolt sensors are more flexible in design to fit into embedded systems and customized equipment.

Millivolt Wiring Schematic

How To Guide

For this how to guide, we have three components; power supply (labeled as 1 in the schematic), Core Sensors pressure transducer, and a meter or other DAQ system (labeled as 2 in the schematic).

1) Power Supply – Connect the positive (+) terminal of the power supply to the +V pin or wire of the transducer. Connect the negative (-) terminal of the power supply to the Ground (GND) pin or wire of the transducer.

2) Meter or other data acquisition (DAQ) –  Connect the COM terminal of the meter of DAQ to the -Signal pin or wire of the transducer. Connect the Volts input terminal of the meter or DAQ to the +Signal pin or wire of the transducer.

This will complete the 4-wire circuit.

* In certain circumstances, there may be an additional pin or wire used as a case ground. This connection is not critical to the output signal but may be critical to maintain listed certifications of the transducer. Please refer to the Core Sensors wiring guides to verify wiring prior to installation.

Common Applications

High Performance Liquid Chromatography (HPLC) – mV sensors are common in HPLC because often the system and pumps are calibrated as a whole and/or the system already has an on-board signal conditioner with trimming features to re-calibrate the equipment when needed. Also, mV sensors can be made as custom embedded units more easily, resulting in lower “dead volume”, which is important in HPLC applications to reduce cross-sample contamination.

Mass Flow Controllers (MFC) – Use of mV sensors in MFCs is common for similar reasons as the HPLC, with the additional need for fast response time. The fast response time of mV sensors in the MFC is vital to fine tune the amount of product that is allowed to flow into the process.

Scales and weighing equipment/hydraulic press and forming – mV sensors are used in hydraulic weighing and machine press applications to replace load cells. The mV output of the sensors is similar to the mV output of many load cells, allowing OEMs to minimize system redesign when upgrading from a load cell to a pressure sensor.

Higher ambient temperature applications – In applications such as super-heated steam, downhole drilling and MWD, or applications measuring pressure in a engine compartment of a moving or stationary engine, temperatures can climb to a range that is not compatible with ICs and ASICs. Because of the lack of ICs, mV units can generally be installed in locations that are simply too hot for amplified sensors, and the signal is transmitted to a remote signal conditioner. The CS-HTP high temperature pressure sensor and CS-90 downhole pressure sensor are recommended for applications where high temperatures are a concern.

Heating, Ventilation, Air Conditioning, and Refrigeration (HVAC/R) – There are numerous applications in HVAC/R systems where pressure is measured. Often, there is a need for two separate sensors to be used to measure pressure in two spots to provide operators with the differential pressure reading. These PLCs are designed to accept two mV signals and report the differential pressure. The CS10 industrial pressure transducer with a millivolt output signal would be an ideal solution to handle this type of application.

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2-wire loop powered

4-20mA Wiring Schematic – How To Guide

For this how to guide, there are three components; power supply, Core Sensors pressure transducer, and a meter or other DAQ system.

1) Power Supply – The first component to the current loop is the power supply, capable of delivering 10-28VDC. The positive (+) terminal of the power supply is connected to the +V pin or wire of the transducer.

2) Core Sensors Pressure Transducer – The -V pin or wire of the transducer is connected to the milliamp input terminal of the meter or DAQ.

3) Meter or other data acquisition (DAQ) – The Common (COM) terminal of the meter or DAQ is then connected to the negative (-) terminal of the power supply. This final step is important as it completes the current loop.

* In certain circumstances, there may be an additional pin or wire used as a case ground. This connection is not critical to the current loop but may be critical to maintain listed certifications of the transducer. Please refer to the Core Sensors wiring guides to verify wiring prior to installation.

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Liquid level sensors are a cost-effective solution for monitoring various types of liquids and are not negatively affected by foaming or reflection.

Liquid level sensors, also known as hydrostatic level sensors, measure level by converting the pressure of a liquid based on its height above the sensor and its density into a linear output signal. Liquid level sensors are a cost-effective solution for monitoring various types of liquids and are not negatively affected by foaming or reflection. Core Sensors has a solution for both industrial tank level applications and applications in Intrinsically Safe rated locations.

There are various installation methods that can be used when monitoring level with a pressure transducer:

Submersible

Vented Tank

The most common installation method is fully submerging and lowering a submersible designed sensor to the bottom of the tank or vessel that is being monitored. It is important to ensure that the sensor is at the very bottom of the tank to provide the most accurate level readings (see Figure 1). Submersible sensors are used in vented tanks and the sensor itself features a wide diameter vent tube that runs the length of the cable and terminates with the rest of the conductors. This vent tube allows the sensor to correct for any changes in barometric pressure which, in shorter tanks, is critical for ensuring accurate level readings. Core Sensors offers ETFE as a standard cable jacket material to ensure compatibility in a wide range of medias. Sensors come standard with a 1/2″ MNPT conduit fitting for customers that want to install conduit piping over the cable (see Figure 2). This method of installation is common in applications where the media may not be compatible with the jacket material or in mobile tanks. The conduit fitting will help keep the sensor stationary during tank movement. Core Sensors offers customisable submersible pressure transducers for both industrial and Intrinsically Safe applications.

Figure 1

Example: A Core Sensors submersible pressure transducer lowered to the bottom of the tank with the cable exiting the tank and terminating in a control box or other data acquisition system. The sensor will read its full scale output when the tank is full (or the full scale calibrated pressure of the sensor is reached) and will read its zero output when the tank is empty.

Figure 2

Example: A Core Sensors submersible pressure transducer lowered to the bottom of the tank with a rigid conduit pipe installed over the cable. The conduit pipe is connected to the top of the tank with a reducing tank fitting and the other side connected to the 1/2″ MNPT conduit on the sensor. The cable exits the tank and terminates in a control box or other data acquisition system. The sensor will read its full scale output when the tank is full (or the full scale calibrated pressure of the sensor is reached) and will read its zero output when the tank is empty.

Example: A Core Sensors pressure transducer externally threaded into a Tee fitting at the bottom of the tank with the cable terminating in a control box or other data acquisition system. The sensor will read its full scale output when the tank is full (or the full scale calibrated pressure of the sensor is reached) and will read its zero output when the tank is empty. This same installation method can be used with a differential pressure transducer.?

Externally Mounted

Vented Tank

Standard pressure transducers can be externally threaded into the side of the tank when using a submersible sensor is not ideal (see illustration below). Externally mounted sensors typically cost less than submersible sensors and there are less materials that need to be considered in terms of compatibility. These sensors are vented to atmospheric pressure through a vent tube or vent hole. Externally mounted sensors can be configured with integral cable as well as various connector options including an M12x1 Eurofast for an IP67 rating when used with an appropriate mating cable assembly.

Customers can also choose to install a submersible designed sensor externally with a 1/4″ NPT Male process connection instead of the standard nose cone. This installation method is ideal for environments where flooding is a concern such as ship compartments.

Differential pressure transducers can also be used to measure liquid level in a vented tank. The high side of the sensor, also referred to as P1, is threaded into the bottom of the tank while the low side, also referred to as P2, is left open to atmospheric pressure.

Example: A Core Sensors differential pressure transducer externally threaded into a fitting with the high side (P1) connected to the bottom of the tank and the low side (P2) connected to the top of the tank. The integral cable on the sensor is terminated in a control box or other data acquisition system. The sensor will read its full scale output when the tank is full (or the full scale calibrated differential pressure of the sensor is reached) and will read its zero output when the tank is empty (or the pressure differential across P1 and P2 is equal).

Externally mounted

Sealed Tank

When measuring liquid level in a tank that is completely sealed, it is ideal to use a differential pressure transducer to ensure accurate level measurements. The high side of the sensor, also referred to as P1, is threaded into the bottom of the tank while the low side, also referred to as P2, is threaded into the top of the tank (see illustration below). The sensor then measures the difference in pressure from the top to the bottom of the tank and transmits a linear output signal.

Selecting an output signal

Core Sensors offers various output signals for our liquid level monitoring products.

4-20mA is a popular output selection for applications where the output signal needs to be transmitted over a long distance without worrying about signal loss. This output signal requires a supply voltage of 10-28VDC. The current consumption is higher with a 4-20mA output signal than the other available outputs (20mA, typical).

1-5V is another popular output signal for level applications. This output signal requires a supply voltage of 10-28VDC and has a current consumption less than 10mA. 1-5V output is not recommended for long distance transmissions.

Low power voltage outputs including 0.5-4.5V Ratiometric and 0.5-2.5V Non-Ratiometric are available. These output signals are popular for monitoring in IOT applications and remote locations where energy conservation is top priority. The 0.5-4.5V Ratiometric output signal requires a regulated 5VDC supply and has a current consumption less than 5mA. The 0.5-2.5V Non-Ratiometric output signal requires 3-5VDC of unregulated power with less than or equal to 3mA current consumption.

Liquid level Sensors – submersible, external, differential | Core sensors. (2022, October 21).
https://core-sensors.com/liquidlevelsensors/

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