Retrofit Rechargeable power system

Faced with persistent challenges in the field, I embarked on a comprehensive redesign to address issues related to high battery wastage and short lifespans. The goal was to improve both new product iterations and retrofitting for existing systems where customers were unhappy with performance.

To understand the performance characteristics of current batteries, I initiated a thorough testing phase. Conducting extensive longevity tests under various conditions and comparing multiple battery types, I derived valuable insights that guided my design decisions. I prioritized the integration of larger, more durable 6V lead-acid batteries, which demonstrated superior longevity and offered ease of recharging, seamlessly aligning with the product's dimensions and functional requirements.

In the pursuit of enhancing user convenience and safety, I personally oversaw the partnership with a reliable battery supplier. This supplier provided customized wrapping and suitable flying leads, ensuring optimal handling and operational safety for end-users. My loom design allowed for effortless detachment and reattachment of the battery, enabling users to conveniently recharge the unit away from the main setup. Although not in the brief the unit originally had a 6V power input jack that could be used to power it from mains - I made use of this and built the loom in a manner that would allow this jack to also power the units.

For seamless integration with both retrofit and new product applications, I  used sheet metal for the bracket ensuring it mated with the unit for easy installation and retrofitting in the field. Focusing on sheet metal design intricacies, I ensured a secure attachment to the pre-existing bracket, retaining all prior electronic connectors and effectively supporting the weight of the battery while allowing effortless access for removal, disconnection, and reconnection.

For electrical safety and accreditation, I oversaw every aspect of the battery's integration. From thorough research and specification to SOP for production, I ensured compliance with stringent safety standards and ensured all documentation (Labeling, installation & operation guide) would meet the standard to be sold in the UK and Overseas.