Wireless hand lamp for joint play tester

For main inspection and PTI applications.

Challenge:

Development of a wireless hand lamp for joint play testers including valve control unit with safety functions for PTI applications with a focus on intuitive operation and easy integration into existing customer solutions.

Requirements:

hand lamp:

Robust and shockproof housing
Long battery life
Bright LED
Charging cradle
Intuitive operation of movements
Radio communication in 433MHz ISM band
Belt clip with magnetic attachment

Valve control board:

Easy integration into existing customer solutions
Can be integrated into metal and plastic control cabinets (various antenna solutions)
Movement options can be activated via dongle
Min. 8 control outputs for valves

Solution:

The development goal was a modern and safe overall system consisting of radio hand lamp and valve control board. On the one hand, the focus was on intuitive operation for the end user and, on the other hand, on easy integration of the system for our customers into their existing joint play detectors. The product design took into account Directive 2014/45/EU as well as EU country-specific requirements.

Radio hand lamp technical data:

Very bright LED with lens (1000Lux in 1m distance, according to Italian requirement)
Rechargeable battery with 4,200mAh (min. 12h operating time)
Charging and radio link LED
Belt clip with magnetic holder (rubberized)
Anti-theft retractor with pull-out cord (optional)
Shock- and drop-proof, sturdy IP65 housing with rubber protection
Intuitive operation thanks to clear symbols and LED-status of selected movement
Keypad (customizable with logo, color, symbolism, etc.)
Up to 30m radio range (depending on the selected antenna)
Radio connection 433MHz (8 channels) – toll-free ISM band
Light button (on/off)
Charging station for standing or wall mounting
Dimensions (LxWxH): 143mm x 77mm x 38 mm
Weight: approx. 240g

Movement options:

Opposite movement transverse / longitudinal
Synchronous movement transverse / longitudinal
Single wheel movement right or left (transverse / longitudinal)
Automatic centering
Automatic mode (deadman function), single, pair, co-rotating and counter-rotating
Automatic circular motion, single, pair, co-rotating and counter-rotating
Automatic diagonal movement
Other automatic movements on request

Movement options or other functions can be optionally enabled via option dongle or already integrated in the firmware.

Technical data of the control unit:

Power supply 24V/DC
Radio connection 433MHz (8 channels) – toll-free ISM band
Matching network for compact SMA antenna and external BNC antenna (adjustable via jumper)
RS-485 data bus
Error condition detection (wire break etc.)
Safety channel for error detection
Mounting on top hat rail (top hat rail housing included)
8x switching outputs 24V 1.6A for solenoid valves with LED status display
4x switching output 24V 1.6A for contactors etc.
3x inputs (logic, high, 0.8 – 24V)
6x port for option/variant dongle
1x push button for coupling the radio hand lamp
1x status LED (multicolor)
8x wireless channel LEDs
Dimensions (LxWxH): 145mm x 90mm x 42mm