Intrinsically Safe LED Torch Electronics

A leading manufacturer of intrinsically safe lamps and torches required the design and development of the electronics for a rechargeable ATEX approved torch. This had to be able to work with traditional bulbs or new high-powered LED technology.

The design also had to be lightweight, have a long operational life on one charge and also be approved in line with the automotive directive EC 95/2004.

The Northern Hi-Tec design team met the challenge and produced a design that combined a wide range of in-house skills, including the design of a compact
Switch Mode Power Supply to work on either 12-Volt or 24-Volt automotive electrical systems.

Lithium-Ion battery technology protection / charge / discharge requirements with the added requirement of intrinsic safety provided an interesting, but not an
impossible challenge.

An embedded processor based control and indication system also provided a level of flexibility to allow product variation as well as future product enhancement.

Services provided included:

• Electronic Hardware Design
• Embedded Software Design and Implementation
• Consultation with BASEEFA to meet ATEX Approvals
• PCB Layout
• Prototype Production
• EMC and Automotive Type Approvals
• Liaison with Industrial Design House for Mechanical Constraints
• ATE and Functional Test Development
• Full Scale Cell-Based Production
• Full Supply Chain Management

Manufacturing facilities employed:

• Surface Mount Assembly
• Through Hole Assembly
• ATE Testing for Full Manufacturing Defects Analysis
• Comprehensive Full Functional Testing
• Conformal Coating