Case Study: Battery Charger Design Solution for Fire Fighters’ Infrared Imaging Camera
A leading manufacturer of all types of equipment used by fire fighters and first responders of all descriptions had a problem supporting an important electronic instrument, the infrared imaging camera that makes visible human targets in smoke filled environments. An engineer called SPAN to see if a solution could be found to the battery charging problem.
The problem was how to make a charger fit and firmly hold a really odd shaped battery. The charger also would be mounted in common fire trucks where it must operate under most difficult conditions. Another version would have to operate operate from wall power in the relatively benign environment of the station.
The solution would involve special mechanical design features and tooling for molding a battery receptacle as well as features to reliably connect the battery to the special electronics within the enclosure.
Span engineers in full cooperation with the customer's engineers undertook the project and produced the product that filled the bill. Tooling was accomplished which produced the strong component needed to withstand the difficult environments and accommodate the odd battery shape. Electrical connections were made with special spring loaded pins that could carry charge currents without overheating or becoming contaminated.
Today, many years of production, of reliable field use, the product continues to meet the challenges. It continues to serve the customer and their industry well.
