Custom Battery Packs for Tracking Devices

Tracking devices can be used in hundreds of different applications and are usually powered by high energy density lithium batteries . These devices can be used for everything from overseeing product shipments, tracking the exact location of a wander prone patient, protecting valuable assets, worker safety, and many others.

Because these applications are all critical in nature, custom battery packs that meet the intense requirements of each specific device must be developed. Not only must these custom battery packs be designed and manufactured to provide reliable and long-lasting performance, they must also take into consideration other aspects of these devices such as being tamper proof, not interfering with devices communication components, and being able to perform in many different types environmental conditions.

At a Glance: Battery Packs for Tracking Devices

• Custom battery packs for tracking devices must deliver reliable, long-term power while operating in harsh environments that may include temperature extremes, vibration, dust, moisture, tampering, and EMI/EMC exposure.
• Battery solutions can serve as either a primary power source for active tracking devices or a backup power system that maintains communications and data collection when external power is lost.
• Epec supports tracking applications ranging from GPS asset tracking and lone worker safety devices to ankle monitors, hospital equipment tracking systems, wildlife monitoring tags, and transportation logistics solutions.

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Epec Engineered Technologies has experience in working with many different customers to create custom battery packs for re-usable tracking devices, such as:

• Temperature monitoring during transport (food and pharmaceuticals)
• Cash and stolen property tracking
• GPS systems
• Mobile alcohol monitoring devices
• Lone worker safety
• Over the road truck and container tracking
• Wander management
• Tracking of equipment location in hospitals
• House arrest ankle monitors
• Wildlife tracking and animal monitoring tags
• Retail loss prevention
• Electronic maintenance monitoring
• Location monitoring for pretrial defendants and individuals involved in the immigration process
• And more…

See our case study on the next phase battery pack design for tracking device.

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Battery Pack Requirements for Tracking Devices

Most companies don't develop different tracking devices for all of the different environmental issues that they may encounter. They want to develop one product that is robust enough to be used in any location so they can encounter extreme temperatures, strong winds, tampering, dirt, dust, physical abuse, EMI/EMC interference, and numerous other hazards.

The other key component in these applications is that the custom battery pack is being developed so that the tracking device is reusable, which is the thing that makes the technology affordable to the end customer. This requires that the custom battery packs be designed to withstand years or use and, in many times, abuse.

The tracking industry has gone away from passive tracking devices and have moved almost exclusively to active trackers, also called real-time trackers. These trackers transmit data via satellite or a cellular network, which instantly indicates where the tracker is located, along with other data that the device is programmed to monitor. So, for businesses interested in improving their efficiency, they can monitor their assets or people a computer screen can display this movement in real-time. Here at Epec Engineered Technologies, we have experience in designing both.

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Custom Backup Batteries for Powered Devices

Custom backup batteries for powered devices like vehicles so that they can still communicate and collect data when their power source is powered off.

These devices kick on when the primary input source fails and can no longer power the load and provides power to the system output load via an internal diode and relatively unlimited current if an external diode transistor is used. These custom battery packs provide a seamless switchover between input power and backup power during a power fail event.

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Custom Battery Packs as Primary Power Supply

Custom battery packs that will be the primary power supply for the active tracking device. Constant vibration, harsh environments, and the requirement to operate unattended for years are the norm for tracking devices. These factors become our focus when developing custom battery packs for tracking devices that must support positioning, microprocessor, and communications components, and often temperature and alarm sensors. Our experience here not only includes cell selections , battery management systems (BMS) development, design, and manufacturing, but it also includes integrating charging , enclosure design for reliability, and being able to produce a product that will pass all of the required certifications for each device.

As the demand for untethered tracking devices dramatically increases every year, we continue to work with our customers to find the best new technologies in order to provide solutions that fit their needs in terms of cost, footprint, and longevity.

With new technologies like "geofencing" being developed every year, and with the introduction of new ICs that can do everything faster, it is critical that we stay ahead of the curve to help our customers.

Epec Engineered Technologies has experience in both cellular and two-way satellite tracking systems, which require complex battery systems to operate. Even tracking systems equipped with low-power operational states must consume excessive power to manage two-way communications as well as transmit with sufficient energy to operate within the communications infrastructure.

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Frequently Asked Questions

Quick Links

• What are the key battery pack requirements for tracking devices?
• What is the difference between a primary battery pack and a backup battery pack in tracking applications?
• Why do active tracking devices require specialized battery pack designs?
• How can custom battery packs improve the reliability of tracking devices?
• What types of tracking applications commonly use custom battery packs?

What are the key battery pack requirements for tracking devices?

Tracking device battery packs must provide dependable performance over long service lives while operating in challenging environments. Designs often need to withstand vibration, physical abuse, temperature extremes, dirt, dust, and potential tampering. Because many tracking devices are reused repeatedly, battery systems must also be durable enough to support years of operation while maintaining reliable power delivery and communication capabilities.

What is the difference between a primary battery pack and a backup battery pack in tracking applications?

A primary battery pack serves as the main power source for the tracking device and supports all critical functions, including positioning, processing, sensing, and communications. A backup battery pack activates when the primary power source fails, allowing the device to continue transmitting data and collecting information. Backup solutions help ensure uninterrupted operation during power loss events through seamless power source transitions.

Why do active tracking devices require specialized battery pack designs?

Active tracking devices continuously or periodically communicate through cellular or satellite networks, which places higher demands on battery performance than passive tracking technologies. These systems must provide enough energy to support communications, location services, sensors, and onboard electronics. Specialized battery pack designs help balance power requirements, operating life, size constraints, and reliability objectives.

How can custom battery packs improve the reliability of tracking devices?

Custom battery packs are engineered around the specific requirements of the tracking system and its operating environment. This can include selecting the appropriate battery cells, integrating a battery management system (BMS), incorporating charging functionality, and designing enclosures that protect against environmental hazards. A tailored solution helps maximize uptime, improve durability, and support certification requirements.

What types of tracking applications commonly use custom battery packs?

Custom battery packs are used across a wide range of tracking and monitoring applications. Common examples include shipment temperature monitoring, GPS asset tracking, truck and container tracking, lone worker safety devices, hospital equipment tracking, house arrest ankle monitors, retail loss prevention systems, wildlife monitoring tags, and mobile alcohol monitoring devices. Each application presents unique power, environmental, and performance requirements that often benefit from a custom battery solution.

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Power Your Tracking Devices with Custom Battery Packs

Our custom manufactured battery packs are tailored to your needs! Get a free quote today and ensure reliable, long-lasting performance for your device tracking applications. Request more info now!

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