Lion Collar Payload (primary battery)

Step-by-step production process.

Electronics

  1. primary testing

  2. add GPS antenna

  3. GPS antenna testing

  4. GPS antenna tuning (1592 MHz in air)

  5. remove 2 components from the charger (positions D3 + U13)

  6. remove all components from the top part of the board (above the EMI shield)

  7. add zero-ohm resistor

  8. add EMI shield (temporarily attached in one corner)

  9. add tag extension 21,4 mm + tag (do not solder right-side battery/2,5V pins on the tag extensions)

  10. tape underneath the tag to protect holes for programming from the resin

  11. enlarge holes on the charger (2 mm drill)

  12. battery 5-pack assembly (5x Saft-14250; 3mm x 0.1mm welding strap)

  13. apply hot glue all around the EMI shield (to prevent the resin flowing underneath it)

  14. add foam protection - antenova (12x12x17mm) (note: should be added at the very end, after the application of hot glue)

Mechanics

Enclosure

  1. plastic enclosure production

  2. washing of the enclosure

  3. screw holes indentation on attachment plates

  4. polishing the attachment plates

  5. engraving of serial numbers (laser parameters: power 30%, speed 250 mm/s)

Resin casting

  1. Electrolube PU resin UR5528

  2. cca. 38g/piece

Engraving

Collar

  1. TPU leather flat belt production (BioThane Granite 230 TPU Coated Webbing, colour TN232)

  2. width: 38 mm

  3. length: 1.0 m

  4. logo engraving (cutting: power 100%, speed 10 mm/s, scanning: power 40%, speed 250 mm/s)

Assembly

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