HYDROCLIMA 2 Heat Cost Allocator Production

Project Overview

We successfully implemented a full-scale production process for the HYDROCLIMA 2 – a high-precision, dual-sensor electronic heat cost allocator designed by our client. This project showcases our expertise in industrializing complex electronic products, from advanced assembly techniques to custom testing systems, all within a high-volume manufacturing framework.

Client Challenge

Our client, a prominent metering solutions provider, developed the HYDROCLIMA 2: an advanced wireless-enabled heat cost allocator equipped with dual temperature sensors, integrated tamper detection, and long-range data transmission using Wireless M-Bus. To bring this innovative device to market, they required a manufacturing partner capable of:

  • Handling mass production without compromising precision

  • Implementing stringent quality assurance and traceability

  • Designing a customized testing platform for functional verification

  • Managing the entire production cycle, from PCB assembly to final testing and packaging

Our Solution

We engineered and optimized a complete, end-to-end production process including:

Advanced Manufacturing

  • SMT (Surface Mount Technology) assembly for high-density electronic components

  • THT (Through-Hole Technology) for mechanically robust or high-power components

  • Mechanical assembly of enclosure, display, and sensors

  • Microcontroller programming with client-provided proprietary firmware

Intelligent Testing & Quality Control

To ensure every unit meets design and regulatory standards, we developed a dedicated parametric-functional tester, purpose-built for the HYDROCLIMA 2. This system performs:

  • Precision sensor calibration within 1% accuracy

  • Wireless M-Bus protocol validation

  • Battery and power consumption diagnostics

  • Display and interface checks

  • Multi-range temperature response testing

  • Verification of tamper detection mechanisms

Process Optimization

Our production line was meticulously optimized to balance throughput and reliability, ensuring both scalability and the high precision required for devices used in regulated cost allocation systems.

Results

Our collaboration delivered tangible outcomes:

  • High-reliability devices with a projected 10-year battery life

  • Mass production capabilities meeting growing market demand

  • Exceptionally low defect rates due to automated, in-depth testing

  • Full compliance with EU directives and standards (including PN–EN834, PN–EN60950, RED, and EMC)

Why It Matters

The HYDROCLIMA 2 sets a new benchmark in energy metering by enabling precise, usage-based heat billing in multi-dwelling buildings. By ensuring accurate performance and long-term reliability, these devices promote energy efficiency and cost transparency for end-users.

This project exemplifies our ability to transform a client’s design into a scalable, production-ready product through cutting-edge manufacturing and intelligent test engineering — reinforcing our position as a trusted partner for complex electronic device industrialization.

Published:
November 11, 2024
Category:
Production
Client:
BMETERS

Related Projects