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Isolated probing tech for fast-switching power device testing

Keysight Technologies has developed an optically isolated differential probing family dedicated to enhancing efficiency and performance testing of fast-switching devices such as wide-bandgap GaN and SiC semiconductors. Validation of floating half-bridge and full-bridge architectures commonly used in power conversion, motor drives, and inverters requires measurement of small differential signals riding on high common-mode voltages. This measurement can be challenging due to voltage source fluctuations relative to ground, noise interference, and safety concerns.
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Protect sensitive electronics in explosive environments with new aluminum ATEX Cabinet Cooler Systems

EXAIR's ATEX Cabinet Cooler^® Systems deliver a powerful and affordable solution for keeping electrical enclosures cool in hazardous ATEX classified areas -- and they're now available in durable aluminum construction. Engineered for use in Zones 2 and 22, these coolers are UL tested, CE compliant, and meet stringent ATEX standards for purged and pressurized enclosures. With cooling capacities up to 5,600 Btu/Hr., ATEX Cabinet Coolers are ideal for preventing overheating in electrical cabinets. EXAIR offers a comprehensive lineup of systems.
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PLC handbook chock full of must-know information

Automation-Direct's Practical Guide to Program-mable Logic Controllers Handbook has been improved with tons of new need-to-know info, making it a more comprehensive guide to the world of PLCs. Besides covering the basics of PLC history, PLC hardware, and PLC software, this guide takes you deeper into the ever-changing world of PLC communication, the importance of feedback loops, cyber security, and many other areas that are a must-know for any PLC novice or seasoned automation professional.
Get this great resource today.

Haptic feedback prototyping kit from TDK

Get your customers to feel the difference your products make. TDK has released a development starter kit for fast haptics prototyping. It gives mechanical designers and engineers first impressions of the haptic feedback using PowerHap piezo actuators, shows how the mechanical integration works, and provides a reference design. Applications include automotive, displays and tablets, household appliances, vending machines, game controllers, industrial equipment, and medical devices.
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Mini ESD preset torque screwdriver

Need precision fastening with ESD protection at the smallest torque levels? Mountz has you covered. The new FG Mini ESD Preset Torque Screwdriver is built for low-torque, high-precision tasks. Its compact design makes it ideal for tight spaces and small fasteners, while delivering the same reliable control and ESD protection users have come to expect from Mountz. Two models available: FG25z (3 to 25 ozf.in, 2 to 17.7 cN-m) and FG50z (20 to 50 ozf.in, 14.1 to 35.3 cN-m).
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Laumas load cells and electronics from AutomationDirect

Automation-Direct has added Laumas precision-engineered load cells, transmitters, and accessories that deliver reliable performance in industrial weighing and force measurement applications. The FCAL series high-precision bending beam load cells are ideal for low- to mid-capacity systems. CTL series load cells are designed for both tension and compression, with excellent linearity. The CBL series low-profile compression load cells are perfect for space-limited applications. Laumas load cell transmitters are available too for precise monitoring and control. Very good pricing.
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Engineer's Toolbox: What is ground loop feedback?

Improper grounding can create problems in data logging, data acquisition, and measurement and control systems. One of the most common problems is known as ground loop feedback. Experts at CAS DataLoggers run through five ways to eliminate this problem.
Read the full article.

What is a braking resistor?

According to Automation-Direct, "Braking resistors don't actually provide braking directly -- rather, they allow a drive to stop a loaded motor faster." Why is this important? Protect your AC or DC drive system from regenerative voltage that can create an over-voltage fault on the drive -- especially with high inertial loads or rapid deceleration.
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New Digital Static Meter: Precise measurement, easy use

Static electricity isn't just a nuisance; it's a serious threat to manufacturing efficiency, product integrity, and workplace safety. Unchecked static can lead to costly downtime, product defects, material jams, and even hazardous shocks to employees. If static is interfering with your processes, EXAIR's upgraded Model 7905 Digital Static Meter offers an essential first step in identifying and eliminating the problem. With just the press of a button, this easy-to-use, handheld device pinpoints the highest voltage areas in your facility, helping you diagnose static issues before they become a problem.
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New laser cutting modulating strategy tested with Mikrotron high-speed camera

Modulating a laser beam's intensity distribution optimizes energy delivery to the process zone, resulting in better cutting speed, cut edge quality, and cut kerf geometry. Scientists in Belgium have come up with a new method that they say produces better cutting results.
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All-in-one embedded PLC based on Raspberry Pi 4 -- build control applications

The new PLC CPI-PS10CM4 from Contec Co. is a compact embedded programmable logic controller (PLC) that is loaded with CODESYS, the world's most widely used software PLC. This product uses Contec's original single-board computer, which is based on Raspberry Pi's latest embedded module, the Compute Module 4 (CM4). By using the wide range of peripheral devices for Raspberry Pi, such as Contec's CPI Series, you can build various control applications in a PLC language that complies with the IEC 61131-3 international standard.
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Torque sensors for fastening applications and more

Saelig Company has introduced the Sensor Technology SGR525/526 Series Torque Sensors to provide precision torque monitoring that is critical for performance and safety. The square drive design (for applications with non-cylindrical shafts) allows for seamless integration into power tools, test rigs, industrial machinery, and precision fastening applications, ensuring superior torque measurement without the need for additional adapters or modifications. The SGR525 offers torque measurement only, while the SGR526 provides torque, speed, and power measurement using a 360-pulse-per-revolution encoder. Industries include automotive, aerospace, manufacturing, and research and development.
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Wide-angle camera optimized for larger, faster conveyor belts

Wider conveyor belts operating at higher speeds are now commonplace in modern logistics. To keep up, SVS-Vistek is offering a cost-effective alternative to multi-camera systems with its fxo901CXGE 10-GigE color camera featuring the Sony IMX901-AQR wide-aspect global shutter 16.4-megapixel CMOS sensor. Unlike standard cameras, this unit captures targets in a wide field of view while maintaining high resolutions. The 4:1 horizontal aspect ratio allows one fxo901CXGE to replace an entire multi-camera system, removing the need for image synchronization.
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Handheld thermal imager cuts diagnostic time

The FLIR TG268 is a next-generation thermal imager that provides professionals in the utility, manufacturing, electrical, automotive, and industrial sectors with a lightweight, handheld, affordable condition monitoring tool. Latest enhancements include higher temperature ranges, improved resolution, and larger data storage capacity. Go beyond the restrictions of single-spot IR thermometers to view and evaluate hot and cold spots that may signify potentially dangerous issues. Accurately measure temps from -25 to 400 C. Native thermal images improved with Super Resolution upscaling.
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SOLIDWORKS 2025: Sheet metal design top features from an expert

Find out what's new in SOLIDWORKS 2025 when it comes to sheet metal and weldments, and learn some valuable tips and tricks along the way from TriMech. Topics covered include copying cut list properties, bend notches, tab and slot enhancements, groove beads (a new type of weld bead), performance enhancements, and more. When you're done, check out TriMech's full YouTube channel filled with educational material.
View the video.

Study shows industry-standard fast-charging cycles can ruin an electric car's batteries

An electric car battery before and after industry-standard fast charging. [Ozkan Lab/UCR]

 

 

Commercial fast-charging stations subject electric car batteries to high temperatures and high resistance that can cause them to crack, leak, and lose their storage capacity, conclude engineers at the University of California, Riverside in a new study published in Energy Storage. To remedy this, the researchers have developed a method for charging at lower temperatures with less risk of catastrophic damage and loss of storage capacity.

Mihri Ozkan, a professor of electrical and computer engineering, and Cengiz Ozkan, a professor of mechanical engineering in the Marlan and Rosemary Bourns College of Engineering, led a group that charged one set of discharged Panasonic NCR 18650B cylindrical lithium-ion batteries, found in Tesla cars, using the same industry fast-charging method as fast chargers found along freeways.

They also charged a set using a new fast-charging algorithm based on the battery's internal resistance, which interferes with the flow of electrons. The internal resistance of a battery fluctuates according to temperature, charge state, battery age, and other factors. High internal resistance can cause problems during charging.

The UC Riverside Battery Team's charging method is an adaptive system that learns from the battery by checking the battery's internal resistance during charging. It rests when internal resistance kicks in to eliminate loss of charge capacity.

For the first 13 charging cycles, the battery storage capacities for both charging techniques remained similar. After that, however, the industry fast-charging technique caused capacity to fade much faster -- after 40 charging cycles the batteries kept only 60 percent of their storage capacity. Batteries charged using the internal resistance charging method retained more than 80 percent capacity after the 40th cycle.

At 80 percent capacity, rechargeable lithium-ion batteries have reached the end of their use life for most purposes. Batteries charged using the industry fast-charging method reached this point after 25 charging cycles, while internal resistance method batteries were good for 36 cycles.

Difference in charge capacity from industry vs. internal resistance charged electric vehicle batteries. [Sebastian et. al.]

 

 

"Industrial fast charging affects the lifespan of lithium-ion batteries adversely because of the increase in the internal resistance of the batteries, which in turn results in heat generation," doctoral student and co-author Tanner Zerrin said.

Worse, after 60 charging cycles, the battery cases cracked, exposing the electrodes and electrolyte to air and increasing the risk of fire or explosion. High temperatures of 60 C/140 F accelerated both the damage and risk.

"Capacity loss, internal chemical and mechanical damage, and the high heat for each battery are major safety concerns, especially considering there are 7,104 lithium-ion batteries in a Tesla Model S and 4,416 in a Tesla Model 3," Mihri Ozkan said.

An electric vehicle battery with chemical damage after industry-standard fast charging. [Ozkan Lab/UCR]

 

 

Internal resistance charging resulted in much lower temperatures and no damage.

"Our alternative adaptive fast-charging algorithm reduced capacity fade and eliminated fractures and changes in composition in the commercial battery cells," Cengiz Ozkan said.

"The proposed adaptive fast charging provides a novel perspective for the design of fast-charging technology for electric vehicles with better safety performance and longer battery lifespan," said Bo Dong, a doctoral student and paper co-author.

The researchers have applied for a patent on the adaptive internal resistance fast-charging algorithm that could be licensed by battery and car manufacturers. In the meantime, the UCR Battery Team recommends minimizing the use of commercial fast chargers, recharging before the battery is completely drained, and preventing overcharging.

Source: University of California, Riverside

Published March 2020

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