Battery-Powered Compact Flowmeter for the Fuel Industry
Our client, a leading player in the fuel industry, approached us with a request to design the electronics for a compact flowmeter to be integrated into their installations. The flowmeter needed to meet several stringent requirements:
- Operate on battery power with a minimum autonomy of 2 years
- Include an integrated real-time clock with a calendar
- Function reliably across a wide operating temperature range (outdoor use)
The Challenge
The main challenge was to develop a solution with extremely low power consumption, even with an active display showing real-time measurements. Additionally, the device had to be compact, cost-efficient, and robust for outdoor environments.
Our Solution
To address these challenges, we implemented the following:
- Power Management: The device is powered by two standard AAA alkaline batteries, ensuring easy replacement and cost efficiency. We selected an ultra-low-power 8-bit microcontroller with an integrated LCD controller to minimize energy usage.
- Energy-Efficient Firmware: Our custom firmware dynamically manages the microcontroller’s operating modes, significantly reducing power consumption while maintaining continuous operation of the LCD display.
- Customized Display: Clear visibility in outdoor environments and ultra-low power.
- Built-in Real-Time Clock (RTC): Calendar functionality for time-stamped data, provides accurate time and date for logged measurements.
- Enhanced Functionality: After a detailed analysis of competitive products, we suggested and implemented additional features:
- Real-time display of current flow and totalized volume
- A built-in data logger to store recent measurements
- Statistical analysis tools for better performance insights
Production and Testing
To ensure smooth mass production, we developed a dedicated assembly station for the mechanical integration of the flowmeter components. Additionally, a final product testing system was designed to validate the quality and performance of each unit.
After the successful completion and evaluation of a pilot batch, full-scale production of the flowmeter commenced at INVENTRONICS.
Results
The resulting product not only met but exceeded client expectations, offering superior autonomy, functionality, and durability. This innovative flowmeter is now being used in demanding outdoor applications within the fuel industry.
