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Development of CTA-2045 Complaint Universal Communication Module for a Leading US-Based HVAC System Manufacturer

Banner Mechanical Design Engineering Consumer Electronics

Client Overview

US-based manufacturer of HVAC system and water heaters for residential/commercial buildings.

Business Need

  • 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

  • Prepared conceptualization sketches ​
  • IP24 enclosure design​
  • 3D proto typing in DFM for form factor validation​
  • Mold tooling – Hard mold >250K unit production capability​
  • Silk screen printing process for logo, IO port and LEDs​
  • Translucent Light pipe for LED indication​
  • Gray color enclosure​
  • IP24 testing ​
  • Mass manufacturing >5K units​
  • Mold maintenance​
  • IP24 rated enclosure design as per CTA-2045 specification​
  • Manual testing using EPRI Standard SGD(smart grid device) Simulator for UCM AC Mod

Solution Diagram

Diagram Mechanical Design Engineering Consumer Electronics

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​
  • Helped client in reducing 40% time to market for their solution and enhancing user experience and interoperability​

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Success Stories