Development of CTA-2045 complaint Universal Communication Module
Overview
US-based manufacturer that produces heating, cooling, water heating, pool/spa heating, and commercial refrigeration products.
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Challenges
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
Solution
We 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
Outcomes
- Enabled client in increasing the market reach by delivering the mechanical enclosure with customized thumbscrews to make installation as per CTA 2045 guidelines
- Our 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
