Embarking on product development is not only an innovative journey for a company, but sometimes a necessary one. T-T, based in Cheshire, were soon to recognise existing problems with the usability and reliability of a supplier’s float switch and thus took the initiative to combat the issue with its own range of float switches. When there was not a suitable product in the market place to meet the demands of the industry, the company were inclined to improve the situation by developing a range of float switches that were optimised to solve current issues and instil confidence among users, something that is inherently important when controlling sensitive liquids.
Float switch development stage
T-T began the development back in 2010 with its in-house design engineers and the combined expertise of a design house in order to format a structural composition of the product. Furthermore, merging a technical team that had a combined knowledge of over 50 years with some of T-T’s newest recruits, who had a fresh perspective to complications arising during level control, allowed design engineers to come up with a shape with no flat surfaces, a basic volume and shape as a starting point for the process. With continuous review of the design, utilising both internal and external design
consultants, and after optimising the volume of the float switches at the initial review stage, T-T had a product design to progress.
Float switch testing stage
Once the finalised prototypes had been developed, the testing procedure commenced. The trials began in 2011 at T-T’s in-house facilities with continuous operations of all float switches within the range continually pumping over a six month period on three minute cycles. This allowed the company to monitor any complications, faults or issues during this period of rigorous durability testing.
Further in-house testing measured impact resistance, something that was an additional criteria developed by T-T, to further ensure reliability when the float switches entered the market. Alongside this, T-T also acknowledged the requirement for flexibility in cable length, ensuring its new range of float switches would come in lengths of up to 40m, particularly in relation to the Atex and IECex version. This therefore required further investment and consideration, due to the pressures encountered with deep submersion, ensuring its float switch range was capable of withstanding such forces. Again, this was fully tested over numerous years to ensure the design was able to cope in these circumstances. Additional comprehensive assurances carried out by the company included testing the internal switch operation during the manufacturing process and
also full immersion for IP integrity, and temperature controlled testing.
Float switch installation & further testing
As well as using its in-house facilities once reliability was proven T-T started to insert float switches on live pumping stations around the country as part of standard installation and servicing visits. With these sites closely monitored, T-T outlined any technical problems the floats could potentially experience in a variety of wet well’s and applications and resolved them to allow for efficient operation eventually resulting in a product that was suitable for multiple liquids and conditions.
Investing in float switches for the long term
As with any new product development, due to the lengthy time required and the range of resources, it can become an expensive and time consuming process. However, T-T took the commercial view to fully invest in all aspects of the testing procedures to ensure its product would succeed when entering the market and become compliant with the stringent requirements of manufacturing in the UK, which meant also employing specialist external verifiers and test houses.
Product focus: FLO101 float switch
One such example is the FLO101 float switch within the range, which received substantial investment in order to meet the demands of the industry. T-T developed the FL0101 to be its ATEX
and IECEx approved model. After completing extensive research into notified bodies which could assist with the compliance, this resulted in the selection of Element Materials. Element Materials, working closely with T-T’s dedicated Quality Assurance and Product Development Coordinator Anthony Brisbourne, carried out extensive testing of the product ensuring T-T produced an ATEX and IECEx compliant product deemed officially suitable for zone 0 applications and low current switching. FLO101 contains a special low current microswitch, which when used with an ATEX/ IECEx approved barrier, it is compatible with the voltage and current requirements of intrinsically safe systems, such as areas designated as hazardous gas environments.
Quality testing for the FLO range
All float switches within the FLO range were subject to the same rigorous internal and external testing procedures. The FLO102 and FLO103, for general purpose use, the FLO106 for use in diesel oil, and the FLO107 using WRAS approved materials for use in potable water, have all been reviewed by compliance advice companies, such as the CE marking association, and evaluated against the necessary standards and directives such as low voltage directive.
Furthermore, T-T has developed a series of detailed supporting documentation for its product line. The company recognised the requirement that the end user had for on-hand technical advice in
multiple formats and have therefore spent considerable time developing a series of datasheets and operating and instruction manuals. Unlike the traditional manuals, the Float Switch range manuals were designed with simplicity in mind. After multiple edits, T-T finally settled on pictorial installation diagrams to demonstrate how the product functions. This was complemented by the required technical information on the rear of the fold-out style manual and the format was mimicked for T-T’s new range of counterweights. As the product went through development the manuals were constantly revised to suit any requirements and amendments to the float switch.
Float switches for the UK and beyond
As a product designed and manufactured in the UK T-T feel confident that this product will not only be popular for the domestic market but will also generate great interest for export customers too. As a fully British manufactured product, the range has been optimised for liquid control internationally, with considerations for uses in this worldwide market evident from conception. Already receiving a lot of positive feedback, T-T envisage distribution will be in full flow by the end of 2016. As with any new product or procedure, T-T always appreciate feedback from its customers so please do not hesitate to get in contact with the sales team on 01630 647200 or email at response@ttpumps.com.
For any further information on the range visit the website: https://www.ttpumps.com/