Don’t overdesign your battery for IIoT applications

By Sol Jacobs, VP and General Manager

Tadiran Batteries

The rapid expansion of the Industrial Internet of The proliferation of wireless technology has led
Things (IIoT) has impacted every sector of industrial to increased demand for various consumer and
automation. industrial grade batteries. Since every device is unique
in terms of its energy requirements, care must be
The IIoT enables greater use of data intelligence taken to specify the right battery in order to avoid an
by combining ‘big data’ analytics and artificial overdesigned solution.
intelligence (AI) to enhance M2M communications
and interoperability, improve workflow, maximize Is extended battery life an important
operational efficiencies, support quality improvement, consideration?
and allow for the deployment of predictive analytics
to proactively schedule equipment maintenance and Many wireless devices found throughout a factory
equipment rebuilding programs. IIoT communications floor are easily accessible, operate at moderate room
infrastructure is being further extended by scalable temperatures, and can be routinely replaced without
technology platforms that are cloud-accessible and disrupting daily operations. When extended battery
fully interoperable. life is not a critical consideration, it creates the ideal
scenario for using consumer grade alkaline and lithium
Remote wireless connectivity has enabled rapid batteries.
expansion of the IIoT by eliminating the traditional cost
hurdles associated with hard-wiring, since it can cost Conversely, if the application requires extended battery
$100 or more per foot to hard wire any device, even a life, especially in extreme environments, then an
light switch. Eliminating the need to hard-wire a device industrial grade battery is usually required. A common
increases opportunities to deploy systems control and example involves wireless mesh networks that consist
data automation (SCADA), automated process control, of packs of highly scalable nodes (or motes) that collect
quality assurance, asset management, safety systems, and relay data and manage network performance and
machine-to-machine (M2M) interfaces, and related security using Time Synchronized Channel Hopping
technologies. (TSCH) technology.
Advancing Automation eBook Vol. XIV
Extended battery life is influenced by the cell’s annual the following parameters as part of the vendor
energy usage and its annual self-discharge rate. evaluation process:
Battery operating life can be extended through the
use of low power microprocessors, components, and Operating voltage affects the number of cells – Basic
circuitry, along with the use of energy-conserving low math tells you that it requires more than twice as many
power communications protocols such as ZigBee, 1.5v cells to deliver the same voltage as a single 3.6v
WirelessHART, LoRa, or IEEE 802. 15.4e, as well as WiFi cell. Selecting a battery that delivers higher voltage
and cellular phone technologies. could save money by requiring the use of fewer cells
and/or reducing the size and weight of the device.
The vast majority of low-power wireless devices use
primary (non-rechargeable) lithium batteries that operate Extreme temperatures can have an effect on
mainly in a ‘stand-by’ state that draws little or no voltage – Exposure to extreme temperatures reduces
current, awakening periodically or at pre-programmed battery voltage under pulse. If you select a battery
intervals to query the data and awaken only if pre- with a limited temperature range, then deploy it in a
set data thresholds are exceeded. Through intelligent harsh environment, you may need to specify oversized
design and manufacturing, low-power wireless devices batteries in order to compensate for an expected drop
often exhaust more available battery capacity through in voltage under pulsed load. One solution is to utilize
annual self-discharge than is a bobbin-type lithium thionyl chloride (LiSOCl2) battery
lost from daily activity. that features extremely high energy density (which aids
miniaturization) along with the ability to handle high
pulses at extreme temperatures. Using this type of
extended temperature battery may eliminate the need
for carrying extra capacity and/or voltage in order to
compensate for expected losses in voltage under pulse.

Self-discharge rate affects capacity – Certain

battery technologies suffer from high self-discharge
rates of up to 8% per month, thus requiring a larger
battery to compensate for the expected losses in
available capacity. Alkaline batteries are notoriously
Delivered by helicopter near the North Pole, Oceantronics’ GPS/ice buoy measures wind,
short-lived, albeit inexpensive. In certain situations,
temperature, sunlight, ice thickness, and GPS location of icebergs. The device was originally this type of trade-off may be acceptable if product
powered by a large battery pack (left) using 380 alkaline D cells (54 kg). The redesigned battery
pack (right) substituted 32 bobbin-type LiSOCl2 D cells and four hybrid layer capacitors (HLCs) miniaturization is not an important requirement or the
to reduce size and weight (3.2 kg).
______________________________________
battery is easily replaceable. By contrast, an industrial
Courtesy of Sigred Salo NOAA/PMEL grade battery featuring very low annual self-discharge
could enable the use of a smaller battery or possibly
eliminate the need for future battery replacements. This
When designing any industrial grade wireless device, is an important
you typically face competing requirements of achieving consideration
ideal product performance versus paying the lowest for applications
possible price, with compromise solutions often involving hard-to-
resulting in unnecessarily large and heavy batteries. access locations
While oversized batteries may allow the wireless device where battery
to function, such inefficiency can cost you in terms of replacement
product bulkiness, overly frequent battery replacements, is difficult or
along with added shipping expenses, especially to impossible and
remote, hard-to-access locations. battery failure is not
an option.
In order to make a more informed decision when
specifying a battery, design engineers need to consider

Advancing Automation eBook Vol. XIV

For example, a superior-quality bobbin-type LiSOCl2 Pulse size – Increasingly, remote wireless devices
battery can feature an annual self-discharge rate of connected to the IIoT are requiring high pulses to
just 0.7% per year, thus able to retain over 70% of its support two-way wireless communications and remote
original capacity after 40 years. By contrast, a lesser shut-off capabilities.
grade LiSOCl2 battery made with essentially the same Alkaline batteries are ideal for delivering high rate
chemistry could have a higher self-discharge rate of energy but suffer from major performance limitations
up to 3% per year. While the differential may not seem such as low voltage (1.5v), a limited temperature range
overly large, over time this differential really adds up (0°C to 60°C), a high self-discharge rate that reduces
over time, as the battery that loses 3% of its capacity life expectancy, the inability to deliver high pulses,
to annual self-discharge will exhaust 30% of its original and crimped seals that may leak. Alkaline batteries
capacity every 10 years, making 40-year battery life may need be replaced every few months, resulting in
impossible. a higher cost of ownership, which can be especially
problematic for remote wireless applications.
Power or energy – It’s easy to confuse the need for
power (a measure of short-term energy consumed) with For example, the popular CR123A 3.0v lithium
the total amount of energy required (battery capacity). manganese oxide (LiMnO2) battery can deliver twice
Certain wireless devices are designed for infrequent the voltage of an alkaline cell, which can reduce the
use but must operate reliably to deliver continuous high total number of batteries required. However, CR123A
pulse energy for relatively brief periods of time without batteries cannot deliver high pulses, making them ill-
consuming large amounts of total capacity. suited for two-way wireless communications.

Be aware that most commercial battery technologies are Standard bobbin-type lithium thionyl chloride (LiSOCl2)
not designed to deliver a high power-per-energy ratio, batteries are ideal for long-life low-power applications
thus demanding the use of a greater number of cells but are not designed to deliver high pulses due to their
to compensate for their low pulse design. As a result, low rate design, as they can experience a temporary
compromise solutions often require the use of oversized drop in voltage when first subjected to a pulsed
or additional batteries, which results in added bulk and load: a phenomenon known as transient minimum
unneeded capacity. voltage (TMV). One way to minimize TMV is to use
supercapacitors in tandem with lithium batteries. While
popular for use in consumer
LiSOCL2 LiSOCL2 Li Metal Oxide Li Metal Oxide Alkaline LiFeS LiMnO
electronics, supercapacitors
2 2

Bobbin-type with
Hybrid Layer Bobbin-type
Modified for
high capacity
Modified for
high power
Lithium Iron
Disulfate
CR123A are not ideal for industrial
Capacitor
applications due to limitations
Primary Cell

that include bulkiness, a high

annual self-discharge rate, and
Energy Density (Wh/1) 1,420 1,420 370 185 600 650 650 a limited temperature range.
Power Very High Low Very High Very High Low High Moderate Solutions involving multiple
Voltage 3.6 to 3.9 V 3.6 V 4.1 V 4.1 V 1.5 V 1.5 V 3.0 V
supercapacitors also require
Pulse Amplitude Excellent Small High Very High Low Moderate Moderate
the use of balancing circuits,
Passivation None High Very Low None N/A Fair Moderate
which adds cost and requires
Performance at Elevated
Excellent Fair Excellent Excellent Low Moderate Fair additional energy.
Temp.

Performance at
Excellent Fair Moderate Excellent Low Moderate Poor Another sensible solution
Low Temp.
is to combine a standard
bobbin-type LiSOCl2 battery
Operating life Excellent Excellent Excellent Excellent Moderate Moderate Fair

Self-Discharge Rate Very Low Very Low Very Low Very Low Very High Moderate High
with a patented Hybrid Layer
-55°C to 85°C,
can be extended
Capacitor (HLC). The LiSOCl2
Operating Temp. -80°C to 125°C -45°C to 85°C -45°C to 85°C -0°C to 60°C -20°C to 60°C 0°C to 60°C
to 105°C for a
short time
battery supplies background
current in the 3.6 to 3.9v
Table 1 Comparison of Primary Lithium cells

Advancing Automation eBook Vol. XIV

 TLI-1550 (AA) Li-Ion
Industrial Grade 18650
Diameter (max) [cm] 1.51 1.86
Length (max) [cm] 5.30 6.52
Volume [cc] 9.49 17.71
Nominal Voltage [V] 3.7 3.7
Max Discharge Rate [C] 15C 1.6C
Max Continuos Discharge Current [A] 5 5
Capacity [mAh] 330 3000
Energy Density [Wh/l] 129 627
Power [RT] [W/liter] 1950 1045
Power [-20C] [W/liter] > 630 < 170
Operating Temp deg. C -40 to +90 -20 to +60
Charging Temp deg. C -40 to +85 0 to +45
Self Discharge rate [%/Year] <5 <20
Cycle Life [100% DOD] ~5000 ~300
Cycle Life [75% DOD] ~6250 ~400
Cycle Life [50% DOD] ~10000 ~650
Operating Life [Years] >20 <5
Table 2 Comparison of consumer versus industrial Li-ion rechargeable batteries

nominal range, while the HLC acts like a rechargeable transactions or to enable IIoT connectivity that permits
battery to deliver periodic high pulses, thus eliminating motorists to be alerted when an empty parking space
the effects of TMV without requiring a supercapacitor. becomes available.
This hybrid LiSOCl2 battery solution also features
a unique voltage curve plateau when the cell is When selecting a rechargeable battery, be mindful that
approaching its end-of-life. Programming the device to a consumer grade rechargeable Lithium-ion (Li-ion) cell
identify this voltage curve plateau enables the issuance has an expected operating life of approximately 5 years
of ‘low battery’ status alerts. and 500 full recharge cycles. If the device is intended
to operate for more than 5 years and/or 500 recharge
Rechargeable battery cycle life – If the wireless cycles, then additional cells may be required to help
application consumes enough average daily energy reduce the average depth of discharge per cell and thus
to prematurely exhaust a primary (non-rechargeable) extend battery life.
battery, then it could be better suited for a power source
that combines some form of energy harvesting device Also available is an industrial grade Li-ion battery that
with a rechargeable Li-ion battery to store the harvested can operate for up to 20 years and 5,000 recharge
energy. Increased daily energy consumption is often the cycles. Unlike consumer Li-ion rechargeable cells, these
result of more frequent data sampling and transmission. ruggedly designed cells can deliver the high pulses
One example is a solar-powered municipal parking required for powering 2-way wireless communications
meter that routinely draws current to process credit card (15 A pulses and 5 A continuous current) while also
offering an extended temperature range (-40°C to 85°C)
to increase system reliability.

Cheaper can actually be more expensive – While

application-specific requirements invariably dictate the
ideal choice of battery, it is important to think long-term
to determine your total cost of ownership over the
lifetime of the device.

Advancing Automation eBook Vol. XIII

Achieving low initial cost may be important if the device is not intended for long-
term deployment and frequent battery replacement is acceptable. For example,
if the wireless device is situated on the factory and battery replacement is not
disruptive to the automation process, then it may make sense to pay a low initial
price by choosing a consumer grade battery. However, if the wireless device is
intended for long-term deployment in a highly remote and inaccessible location,
then you will need to factor in all anticipated expenses associated with frequent
battery replacement, which will inevitably eat up any initial savings achieved by
specifying an inexpensive consumer grade battery.

The hidden costs associated with an oversized battery solution can also be an
important consideration. For example, a compact and lightweight power supply
can be invaluable to research scientists seeking to exert less physical energy
and burn fewer calories while conducting experiments in frigid Artic conditions.
Compact, lightweight batteries can also be highly beneficial to field personnel who
must service and maintain remote storage tanks, pipelines, and pumping stations.
Excessively bulky and heavy batteries can also increase logistical expenses, as
battery shipment is heavily regulated.

With more and more low-power wireless devices being integrated into the IIoT, including wireless mesh networks
that permit rapid scalability and interoperability throughout industrial automation, it pays to consider the total long-
term cost of ownership when specifying a battery-powered solution.

About the Author

Sol Jacobs
VP and General Manager, Tadiran Batteries
Sol Jacobs has over 30 years of experience in powering remote devices. His
educational background includes a BS in Engineering and an MBA.

Advancing Automation eBook Vol. XIV

You probably already use PROVEN

40
Tadiran batteries,
but just don’t know it!

YEAR
OPERATING

LIFE *

If you have a smart automatic water, gas,

electricity, or heat meter in your home.
If you have an electronic toll collection
transponder, tire inflation sensor, or
emergency E-CALL system in your car.
If you have a GPS tracking device on
your trailer, container, or cargo.
If you have wireless sensors, controls, or
monitors in your factories and plants.
If you use electronics with real-time clock or memory back-up in your office.

If you have never heard of Tadiran Batteries, it is only because you

have never had a problem with our products powering your products.
Tadiran Batteries
Take no chances. Take Tadiran batteries that last a lifetime. 2001 Marcus Ave.
Suite 125E
Lake Success,
NY 11042
1-800-537-1368
516-621-4980
* Tadiran LiSOCl2 batteries feature the lowest annual self-discharge rate of any competitive battery, less than 1% per year, enabling these
batteries to operate over 40 years depending on device operating usage. However, this is not an expressed or implied warranty, as each
application differs in terms of annual energy consumption and/or operating environment. www.tadiranbat.com