Development of CTA-2045 complaint universal communication (UCM) Module

Client Overview

US-based manufacturer that produces heating, cooling, water heating, pool/spa heating, and commercial refrigeration products.

Business Challenge

Upgrading existing solutions to communicate with the smart grid over an established CTA-2045 standard in quick time and integrate it into the overall ecosystem.

VOLANSYS Contribution

VOLANSYS helped the client in designing the universal compliant UCM module:

  • Mechanical design:
    • Prepared conceptualization sketches
    • IP24 enclosure design
    • 3D prototyping in DFM for form factor validation
    • Mold tooling – Hard mold >250K unit production capability
    • Silkscreen printing process for logo, IO port, and LEDs
    • Translucent light pipe for LED indication
    • Gray color enclosure
    • IP24 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 design, development including component selection, architecture, PCB layout, and Gerber release
  • Hardware prototyping including PCB fabrication, assembly, and board bring-up
  • Firmware design and development
  • IP24 rated enclosure design as per CTA-2045 specification
  • Manual testing using EPRI standard SGD(smart grid device) simulator for UCM AC module
Technologies | Engineering Expertise

Mechanical Design Engineering | Hardware Engineering | Embedded Engineering | QE

Application Diagram

Universal communication Module Diagram

Benefits Delivered
  • Enabled client in increasing the market reach by delivering the mechanical enclosure with customized thumbscrews to make installation as per CTA 2045 guidelines
  • VOLANSYS domain expertise helped the client in reducing 40% time to market for their solution
  • Greater interoperability achieved between compatible products manufactured by the client and other manufacturers for enhanced user experience
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