Overview
In this project, we developed a stronger, more sustainable power system for both new units and retrofits, addressing common field issues with disposable batteries such as waste and short lifespans. We chose to upgrade to 6V lead-acid batteries due to their durability and rechargeability. Developing batteries with a wiring design allowed recharging in place or removal for external charging. We also created a robust sheet metal bracket that supported the battery's weight and ensured easy installation, disconnection, and reattachment in the field.

‍Methodology
We began by stress-testing multiple battery types to analyse their efficiency and longevity. The results showed that 6V lead-acid batteries offered the best balance of performance and recharging convenience. Working with a trusted supplier, we developed wiring batteries with flying leads which allowed either in-unit or external charging. To ensure compatibility with both new and existing units, we built a robust sheet-metal bracket for the battery, providing structural support and easy accessibility.

‍Results Discussion
The redesign replaced wasteful disposable batteries with durable, rechargeable 6V lead-acid units, extending lifespan and minimising battery wastage. By implementing the customised wiring system, we provided flexible charging options. The new sheet-metal bracket not only supported the heavier batteries but also made installation and servicing faster and easier. To ensure safe operation, we provided clear labeling and instructions that met both UK and international compliance standards. Overall, the redesign improved efficiency, reduced waste, and gave the client a power system that was both tougher and easier to use.