Sentineo - Thermovault cooperation
State-of-the-art control modules designed by Sentineo connect households worldwide to ThermoVault's global energy-saving platform
Thermovault turned to Sentineo to improve the electronic system of its control modules and optimize it for large-volume production. These modules are designed to interface with its innovative energy saving and demand response platform controlling the heating systems of thousands of households. Often installed in areas with poor signal coverage, the modules were designed to ensure reliable communication in even the most challenging environments. In addition, since the mains are also interfaced, custom high-voltage design has been addressed while maintaining the module’s compact form factor. Finally, Sentineo’s experts assisted to achieve EMC pre-compliance and prepared the system together with Thermovault for mass production. In under four months, Thermovault has been able to achieve formal EMC compliance and successfully step up towards high-volume production.
Reducing the energy bills of households worldwide
Thermovault is pioneering a decentralized global network of connected heating appliances across thousands of households. Sentineo played an important role in the development of compact control modules, which ensure optimal energy flows of electric water boilers, storage heaters and heat pumps across the network. The platform’s self-learning algorithms dynamically adapt the energy-saving strategy, based on inputs received from across the network. At this point in time, Thermovault is managing over 10MW with its enabling devices.
Sandro Iacovella, CEO of ThermoVault, states that he entrusted Sentineo with the integral electronics design of ThermoVault’s compact control module. “The design challenge involved fitting the communication electronics and mains interface within the small form factor, while preparing for the anticipated EMC compliance of the module. Sentineo’s specialized expertise turned out to be essential in achieving secure, reliable, and robust operation for the control module under all conditions.”
Optimizing low-voltage and high-voltage operation
Obviously, the wireless bidirectional communication between the platform and the control modules must function flawlessly, even when facing poor signal coverage and potential signal interferences. Piet Callemeyn: “Sentineo optimized the metering and actuation controller electronics and the positioning of the communication hardware, including modems for cellular and wifi connectivity. These design optimizations ensured proper control module operation and maximum communication robustness.”
“A key challenge was designing and integrating the interfaced mains into a small-footprint PCB design,” says Piet Callemeyn. “Therefore our specialists closely investigated the PCB stackup early on to safeguard proper high-voltage operation in the module’s small form factor. They also took into account the constraints imposed by creepage and clearance distances. Specialist expertise is absolutely essential in this regard.”
EMC pre-compliance and design for mass production
“This fast-turnaround electronics design project has enabled us to jointly achieve EMC pre-compliance,” Sandro Iacovella, explains. “This effort served as the foundation for successfully acquiring formal EMC compliance soon afterwards.”
A common thread throughout the journey was designing for mass production. Piet Callemeyn, comments: “Our experience with bringing electronics design projects towards commercial scaleup, enabled us to apply various design practices to avoid costly complications further down the process.”
Sandro Iacovella, concludes: “Currently, the control module has been produced in a batch of a couple of thousand items. Sentineo assists us in further building up production as our energy-saving network continues to grow.”
