In industry, especially in warehouse logistics, a stable power supply is essential, as demonstrated by its importance in mobile applications like hand-held scanners. Supercapacitors (supercaps) provide energy storage solutions that intelligently complement conventional battery concepts. Leuze makes targeted use of the technology in its innovative sensor solutions.
Hand-held scanners are used in different scenarios, which each place different requirements on the devices’ power supply. For individual scans, which are often required in storage areas or during inventory taking, the hand-held scanner only requires high peak performance for a short time. The devices are often parked in charging stations and need to be fully operational again after a few seconds. Here it is particularly important that the energy storage system charges quickly so that it is immediately available when needed. A hand-held scanner that is to be operated over a long period of time has different requirements. In shift operation in warehouses or production environments, where the device works continuously for several hours, operating time is the decisive factor. The hand-held scanner must last the entire working day on a single charge without needing to be recharged regularly. In these scenarios, the energy storage system’s energy density plays a greater role because a constant power supply is required over longer periods of time.
The energy storage technology is crucial in both cases: It not only impacts the device’s performance, but also its operating time and energy efficiency. Depending on the application, a supercap or a battery in the form of a rechargeable battery may offer the best possible solution.
Supercap is short for supercapacitor, sometimes also referred to as an ultracapacitor. A supercap is an electrical energy storage device that stands out for its particularly fast charging and discharging capacity. It stores energy mainly electrostatically, i.e. by separating electrical charges at the interface between the electrode and the electrolyte. In contrast, batteries store energy electrochemically, i.e. via chemical reactions in the cell chemistry. The main advantage of a supercap is that it can be fully charged within seconds to provide very high power at short notice. This makes the technology ideal for applications with short-term energy requirements or for bridging power outages.
Supercaps can be divided into different types in terms of storage methods, materials used and their technical properties. In industrial applications – especially in mobile devices such as hand-held scanners – the so-called EDLC type (electrochemical double layer capacitor) dominates. It combines a particularly high cycle stability, short charging times and a robust design.
Essentially, an EDLC supercap consists of two highly porous electrodes, often made of activated carbon. These electrodes are separated from each other by a separator and embedded in a conductive electrolyte. When a voltage is applied, a so-called electrical double layer forms at the interface between the electrodes and the electrolyte.
Multi-purpose hand-held scanners for bar code detection are designed for short but performance-intensive applications. Supercap technology provides the scanners with sufficient energy for several seconds to a few minutes. The devices are recharged very quickly. Hand-held scanners with supercap technology are therefore particularly suitable for applications requiring regular individual scans. Leuze makes the most of the technology with its IT 1960 series’ wireless supercap devices. Because no battery is required, the devices are very light.
In general, supercap technology is not a replacement for batteries. However, it is a more efficient alternative for certain applications: Leuze therefore makes targeted use of this technology for solutions such as multi-purpose hand-held scanners. Extremely fast charging in just a few seconds, a significantly higher number of charging cycles, and low weight make handling easier. Last but not least, system operators benefit from cost savings compared to battery-powered devices.
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