A leading manufacturer of generators for commercial and industrial use. One of the most well-respected brands in the industry. For almost 100 years they have been manufacturing high quality generators in the United States and pride themselves on their breadth of product line and personal service, as well as their passion for continual improvement.
The customer was upgrading and replacing one of their leading models, a portable AC power generator used for back up in power outage situations and remote locations where access to AC power is limited.
Their new generation of generators is uprated from 16A up to 90Amps, and they wanted the new redesigned products to incorporate monitoring of voltage and current, and to indicate power on both single phase and split phase models using an LCD display.
A key factor was to avoid any significant cost increases, since the market competition is fierce, and our customer wanted to introduce the improved design without having to pass on any significant price increase to their customers.
They had investigated several options from suppliers in Asia, but none met their criteria exactly. They also had concerns around the logistics of dealing with a supplier without a US presence.
Although aware of Trumeter, they had previously considered that any Trumeter solution would be too expensive.
TIt was only when they approached Trumeter that they became aware we could provide a cost-effective product with a unique custom solution that would be both innovative and within budget.
We created a 3-piece system consisting of:
- A sensor module
- A power meter display module
- A connecting cable
By incorporating a CT into the sensor module, this system allows the measuring of AC current without adding the cost of traditional current transformers (CT). The modularity design off the system also made it much easier to incorporate the Trumeter custom product into their product design.
The new meter was developed in conjunction with the customer’s team, and measures voltage, current, % load, hours and more in both single and split phases. Previously they had only been able to measure hours and volts, and only on one phase.
The new design also warns the user when an oil change is required as well as providing out of range alarms and the recording of overload time and events. Configuration shortcuts are also available via the Dip Switches, including setting the Max Load.
This was a complex project, dependant on other suppliers of components within the final generator. However not only does the final meter achieve exactly what the customer wanted in terms of updating their equipment both aesthetically and from a functionality perspective, it also allows them to clearly differentiate their product from their competitors.
The Trumeter designed system makes their final product safer and more user-friendly by protecting both the equipment using the generator, and the generator itself, from damage.
As with any project, cost was a crucial factor for the customer. By cleverly eliminating the requirement of an additional CT, our custom system allowed the customer to achieve this goal. The result is a product the customer – and the customer’s customers – love.