Product Design Engineering for GEA2 Wi-Fi Dongle

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

GEA2 Wi-Fi Dongle 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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