Client Overview
US-based leading manufacturer of reliable and energy-efficient water heating products.
Business Challenge
Design and development of CTA-2045-A complaint solution supporting GEA2 connectivity to allow electricity providers to communicate with end uses over a standard interface to help manage the variability of increasing distributed energy resources on their grids.
VOLANSYS Contribution
VOLANSYS designed and developed a CTA -2045- A compliant solution that can allow the users to communicate with the heating appliances using a mobile app via the gateway
- Mechanical Design of Wi-Fi dongle
- Prepared conceptualization sketches
- IP51 enclosure design
- 3D prototyping in DFM for form factor validation
- Mold tooling – Hard mold >250K unit production capability
- Silk screen printing process for IO port and LEDs
- Translucent light pipe for LED indication
- Gray color enclosure
- IP51 testing
- No shrink or gate mark visible at single places
- Defining cosmetic inspection criteria to make sure 0% rejection on product final assembly line
- Mass manufacturing >5K units
- Mold maintenance
- Hardware and firmware design and development of Wi-Fi gateway
- FCC and IC certifications
- Supported GEA2 and Modbus RTU connectivity to end devices
- Cloud connectivity through WPA2 Secured Wi-Fi network
- Bluetooth PIN-based authentication for Wi-Fi provisioning of the gateway
Technologies | Engineering Expertise
Mechanical Design Engineering | Product Engineering | Embedded Engineering | Mobility | QE
Application Diagram
Benefits Delivered
- Delivered wall-mount enclosure design with a good aesthetic which helped the client to attract a new set of customers to convert their legacy devices to smart ones with CTA-2045 compliant solution
- Customer is able to deliver a cost-effective solution for enabling connectivity for legacy devices for existing customers which is helping them to maintain the current market share
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