Client Overview
US-based leading manufacturer of plumbing products and accessories, including leak detector that helps analyze water flow, its usage and provides 24/7 protection with alerts on the mobile application.
Business Challenge
The existing gateway of leak detection sensor was not performing well thus need to re-design water mitigation solution with better aesthetic design:
- Complete home water monitoring
- Monitor the home 24/7 for water leaks and temperature changes
- Leak detection
- Detect both leaking water and dropping temperatures from sensors
- Water damage protection
- Avoid water damage
- Alert the system to automatically shut off the water supply if a leak is detected
- Remotely control main water valve
VOLANSYS Contribution
VOLANSYS helped the client in designing their existing gateway of home water leak detection system and provided support in the overall solution:
- Customized HomeBridge Gateway with a new Mechanical Enclosure
- IP40 enclosure design and conceptual sketches
- 3D CAD design and 2D detailed drawing
- 3D prototyping in DFM and SLA for form-factor validation and field testing
- Designed complex mold with multiple sliders
- Mold tooling ready with T-final samples within the 8-week time
- Vibration and drop testing on the enclosure as per shipment standard
- Silk screen printing process for logo and FCC ID text printing
- Translucent light pipe for logo illume with different colors
- White color enclosure
- No shrink or gate mark visible at single places
- Defined cosmetic inspection criteria to get 0% rejection on product final assembly line
- Provided mold maintenance
- Worked with client on new ID design for a tabletop
- Battery operated
- Low power Zigbee to Wi-Fi gateway
- Communicates with multiple sensors, valves and users
- Production and mass manufacturing support > 10K units
Technologies | Engineering Expertise
Mechanical Design Engineering | Manufacturing | Product Engineering | Embedded Engineering
Application Diagram
Benefits Delivered
- Improved aesthetic design with logo illuminations and reduced form-factor by 25%
- Handled mold complexity with multiple sliders for the bottom part to make ease of overall product assembly
- Efficient Ayla enabled Gateway solution delivered – target price in $higher 20s
- Rapid roll-out of first production with support for volume up to ~10K
- Improved product performance by reducing time to detect and stop water leaks to less than 5 seconds
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