OEM TENS Unit Machine | Dual-Channel Hardware | TOP-RANK
B2B dual-channel TENS unit machines. Engineered with discrete step-up transformers and independent MCU control to deliver stable milliampere neuromodulation without cross-channel voltage degradation.
Product Overview
This TENS unit machine is a clinical-grade, dual-channel electrical pulse generator designed for transdermal neuromodulation and pain gating. It operates by converting low-voltage DC battery power into precise, high-voltage therapeutic pulses directed into the peripheral nervous system. Bypassing entry-level shared-circuit architectures, this hardware utilizes discrete power isolation for each output channel to maintain exact waveform fidelity under varying biological loads. We supply these unbranded PCBA platforms and fully assembled hardware units to digital health brands, medical equipment distributors, and physical therapy networks.
Technical/Engineering Description
The hardware enclosure is injection-molded from impact-resistant, medical-grade ABS polymer. The internal architecture relies on a rigid Surface Mount Technology (SMT) printed circuit board assembled within our Zhejiang production base. To generate therapeutic currents, the main microcontroller unit (MCU) drives independent step-up transformers for each channel. This physical hardware separation means that adjusting the intensity on Channel 1 applies zero voltage drop or frequency interference to Channel 2. The user interface connects via conductive carbon-pill keypads or tactile dome switches rated for 100,000 actuation cycles. Baseline B2B production dictates a 3,000-unit minimum order quantity (MOQ) for custom casing colors and firmware modifications.
Key Features
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Discrete Dual-Channel Isolation
Low-tier stimulators utilize a single power transformer split across two channels. When a patient increases the milliampere (mA) load on one pad, the circuit pulls power from the secondary pad, causing a dangerous fluctuation in stimulation intensity. This PCB layout assigns a dedicated step-up transformer to each output jack. The electrical pathways remain physically and logically isolated. Channel A can deliver a continuous 100Hz high-frequency pulse while Channel B independently drives a 2Hz burst pattern, with absolute zero cross-talk or parasitic power drain.
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MCU Dynamic Load Regulation
Human skin is not a static resistor; epidermal impedance changes constantly during a 30-minute therapy session due to sweat gland activation and capillary dilation. Primitive analog TENS dials experience voltage drift as the skin's resistance drops, causing the current to spike and shock the patient. This machine relies on an active MCU that continuously monitors the output loop. It dynamically regulates the voltage based on real-time impedance feedback, locking the output current strictly to the user's programmed setting and preventing uncalibrated mA spikes.
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Asymmetric Biphasic Waveform Generation
Direct Current (DC) passing continuously in one direction causes an accumulation of positive and negative ions under the respective electrode pads, leading to severe electrochemical skin burns. This generator is programmed to output an asymmetric biphasic square wave. It pushes a strong burst of electrons in the positive phase to trigger the nerve action potential, then immediately reverses polarity with a lower-amplitude, longer-duration negative phase. This exact mathematical inversion balances the net electrical charge to zero, clearing the ions from the skin surface and permitting hours of continuous operation without epidermal damage.
Applications
Orthopedic Post-Surgical Rehabilitation
Prescribed by physical therapists for continuous peripheral pain gating following knee arthroplasty or rotator cuff repair.
Chronic Sciatica Management
Dual-channel deployment allows patients to bracket the L4/L5 lumbar spine while simultaneously stimulating the descending sciatic nerve tract on the leg.
OTC Retail Pharmacies
Shelf-ready transdermal hardware packaged with FDA 510(k) OTC clearance for direct-to-consumer digital health markets.
OEM & Private Label
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Firmware Modification: We modify the MCU C-code directly. OEM clients can dictate specific pre-set programs (e.g., locking the pulse width and rate into proprietary sequential cycles), modify the LCD dot-matrix display UI, and brand the boot-up screen.
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Logistics Routing: SMT board assembly, firmware flashing, and injection molding execute in our Zhejiang industrial base. Final PCBA drop-in assembly, UI button calibration, and retail box kitting route through our Vietnam hub, isolating the finished medical electronics from specific B2B import tariffs before shipping to North America or Europe.
Certifications
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Electrical Safety : Tested and validated against IEC 60601-1 (General Medical Electrical Equipment Safety) and IEC 60601-1-2 (Electromagnetic Compatibility), confirming the hardware does not emit RF interference and operates safely near other clinical monitors.
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Regulatory : Manufacturing QMS operates under strict MDSAP frameworks. Product architecture supports rapid client adoption for FDA Class II 510(k) clearances and EU MDR CE marking.
FAQ
Q: Why does the machine output feel weaker when the battery drops below 30%, even if the MCU indicates it is set to 50mA?
A: Generating a 100mA current across a 500-ohm human skin load requires a momentary voltage spike of approximately 50 Volts. The internal step-up transformers draw heavily on the DC battery cell to achieve this. When battery capacity drops below critical voltage thresholds, the cells suffer voltage sag under high transient loads. The transformer fails to reach the peak 50V output, meaning the true delivered milliampere load drops, despite the MCU continuing to display the target setting.
Q: Can this TENS PCBA architecture be modified to function as an EMS (Electrical Muscle Stimulation) unit?
A: Yes. The hardware components (transformers, MOSFETs, and MCU) are identical. The divergence is purely in the firmware. TENS requires continuous pulse rates to gate pain signals. EMS requires a "contraction and relaxation" duty cycle (e.g., 5 seconds ON, 10 seconds OFF) to physically tetanize the muscle fibers without causing fatigue. We simply flash a different operational C-code profile onto the MCU during the SMT assembly process.
Digital health brands and medical device distributors can request PCBA schematics and firmware modification timelines.
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Specifications
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Device name |
TENS-808 |
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Power sources |
3.7 V Li-ion battery |
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Power supply |
Input: 100-240V AC, 50/60Hz,0.2A; Output: 5V DC, 300mA |
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Output channel |
Dual channel |
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Waveform |
Bi-phase square-wave pulse |
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Output current |
Max. 120mA (at 500ohm load) |
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Output intensity |
0 to 40 levels, adjustable |
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Treatment mode |
TENS, EMS and MASSAGE mode |
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Number of programs |
26 program |
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Pulse rate |
2Hz ~ 120Hz |
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Pulse width |
50uS ~ 300uS |
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Treatment time |
5 minutes ~ 90 minutes |
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Operating condition |
5° C to 40° C with a relative humidity of 15%-93%, |
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Storage condition |
-10° C to 55° C with a relative humidity of 10%- |
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Dimension |
109*55*18mm (L x W x T) |
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Weight |
About 73g |
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Automatic shutof |
1 minute |
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Classification |
BF type applied part, internal power equipment, IP22 |
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Size of electrodes pad |
40x40mm, square |
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Output precision |
±20% error is allowed for all the output parameters |
