Mechanical Designing of Moisture Sensor Solution

Client Overview

A US-based leader in designing and developing innovative measurement solutions for a wide range of applications in petrochemical, energy, environmental, pharmaceutical, semiconductor, and plastics industries.

Business Challenge

The client had developed a moisture sensor, which was an old design, they again re-designed their existing solution, which was large, and it did not fit into the existing solution form-factor. Moreover, they wanted to simplify the costly assembly process in manufacturing, which is associated with their current device.

VOLANSYS Contribution
  • Development of moisture sensor prototype-III that have a new form-factor design which will leverage the Prototype-II electronics and fit into the dimensions of the existing moisture sensor solution
  • Mechanical Enclosure:
    • IP65 enclosure design with small form-factor than Generation-I devices
    • 3D CAD drawing and 2D detailed drawing
    • Faceplate label modifications based on the final design
    • CNC tooling for mechanical proto development
    • IP65 testing
    • Improved final assembly sequence steps and saved product assembly time
  • Hardware Design and Development
    • Schematics entry (OrCAD / Altium)
    • Component placement, PCB layout, and routing (Allegro / Altium)
    • Gerber release
  • Hardware Prototyping and DVT
    • PCB fabrication and assembly
    • HW board bring-up and preparing test plan
    • DVT report
  • EDVT Testing and Validation with Capacitance  Box
    • Basic validation by simulating different level of wetness using capacitance box and calibrate the sensor
  • ROHS, CE and Pressurization Compliance
Technologies | Engineering Expertise

Mechanical Design Engineering | Hardware Engineering | Design Validation and Compliance Testing

Application Diagram

Moisture Sensor Solution

Benefits Delivered
  • Helped client to achieve the IP-65(or higher) certification and reduced the form-factor of the device by approx 45%
  • Improved moisture sensor device with the latest electronics which helped the client to continue serving their customers with the moisture sensor technology for the next 5 years
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