Electronic Data Logger Enclosures

Gemini manufacture data loggers that record in transit information and shock loads. They are widely used in the transport, storage and food handling, as well as in many other areas.

The brief they gave us in 2001 was for new custom designed enclosure with low tooling and manufacturing costs for a range of core products, called Tiny Tag Lite, which needed the battery to be user replaceable, it also had to have an IP54 splash proof, lightweight, case, into which they would be able to fit a variety of logger PCB's.

Our response was a basic injection moulded case design that can be adapted by inserting the moulding tool with interchangeable cores to create different connector configurations, and a splash proof sealing gasket incorporating a tethered, flexible protective cap for the sockets. All the sensors and external connections are already incorporated into the printed circuit board, which simply has to be inserted into the case. This avoids the need for difficult soldering connections inside the case and makes production and assembly much simpler.

The whole base unit with PCB and connectors can be easily removed from its fixed protective cover without use of tools, for quick replacement with a new data collecting unit or to change the battery.

It is still in production today with revised electronics and software in the original case design.

We were later briefed to design another range of data loggers that could function in severe conditions, submerged in 20m of water and at temperatures of 5-85C. The result is a design that not only reflects the data loggers' high performance and ruggedness, but also conveys an air of sophistication and high value.

Our design solution uses a series of simple case and connector components that can be arranged to create bespoke and constantly evolving units as required.

The main body features a 2 shot moulded body with clear polycarbonate window, with the option of an over moulded soft boot for more rugged environments.

Tooling was manufactured in China, shipped to UK for production component moulding and assembly, to give Gemini maximum flexibility for quick turn round, small batch production runs.