Custom Power Meter for Portable Generators

The Customer

This company has been a US manufacturer of high quality generators for nearly 100 years and is one of the most well-respected brands in the industry. They pride themselves in continuous improvement, and were upgrading their leading portable AC power generator model, which is used for power backup in remote locations.

The Challenge

portable generator

The Solution

A dedicated project manager and engineering team worked in close collaboration with the customer from concept to manufacturing.

We first presented concepts to the customer to ensure alignment on vision. During this phase we established that the new meter would measure voltage, current, % load and hours on both single and split phases. Previously, the customer’s system was only able to measure hours and volts on one phase.

After ensuring alignment on this vision, we developed a detailed product specification with careful attention to manufacturing implications. At Trumeter, we recognize that every design decision must be planned with manufacturing in mind in order to effectively project and manage costs.

Our engineering team developed a three-piece system consisting of a sensor module, a power meter display module and a connecting cable. We integrated a current transformer (CT) into the sensor module to measure AC current without adding the cost of a traditional CT. The design includes alarms to warn the user when an oil change is required and records overload time and events. It also makes configuration shortcuts like setting max load available via the DIP switches.

At Trumeter, we are big on verification and validation, and these designs went through a comprehensive Design For Manufacturability (DFM) review to ensure we could manufacture them at the desired cost. Throughout the final manufacturing process, we worked closely with the customer to make sure they hit their market entry date on budget and with sufficient inventory.

Custom power meter designed for the portable generator

The Outcome

Everyone wins with custom product development!