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Development of CTA-2045 complaint Universal Communication Module

Development of CTA-2045 complaint Universal Communication Module

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
    UCM Module

    Outcomes

    Benefits Development of Universal Communication Module UCM​
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