Upgrading Appliances with Smart Tech
Client
A USA Based Startup entering the smart home automation market.
Problem Statement:
The client sought to transform traditional appliances (TVs, air conditioners, power plugs) into smart devices with features like remote control, power consumption monitoring, and seamless integration with existing systems. Physical relay boards to automate tasks such as lighting and air conditioning control, ensuring a user-friendly and efficient smart home experience.
Solution:
Techshlok developed an IoT-based Smart Home Automation System that turns regular appliances into smart devices. Using the MQTT communication protocol, the system connects appliances such as TVs, air conditioners, smart plugs, and relay boards to a central hub. This central hub allows users to control and monitor their appliances from anywhere through a mobile app.
Technical Approach:
1. Research and Planning:
3-Month Research Phase: The first phase involved researching the best communication protocol for the IoT devices. After considering various options, the team chose MQTT protocol which enabled efficient real-time control and communication between devices in the home.
2. Prototype Development:
Hub Development: The central hub was designed to serve as the main controller for the entire system. The hub was developed to connect with smart plugs, relay boards, and other devices, communicating with them via MQTT.
Relay Boards: We developed relay boards that could be installed in key areas around the home. These relay boards were connected to the central hub via MQTT, so users could automate the switching on/off of appliances, manage lights, adjust temperature settings, etc.
Smart Plugs: To enable remote control of non-smart appliances (like lamps, fans, and coffee makers), we used smart plugs. These plugs fit into a regular socket and let users control connected devices via the mobile app. The smart plugs also monitor the power usage of the devices plugged into them, providing insights on energy consumption.
3. Testing and Iteration:
PCB-Based Prototype: A Printed Circuit Board (PCB) prototype was created to validate the functionality of the entire system. We tested the hub's signal-capturing ability, ensuring that it could reliably interface with remote signals from various appliances, as well as communicate efficiently with relay boards and smart plugs.
Smart Plugs and Relay Boards Testing: Both the smart plugs and relay boards underwent rigorous real-world testing to ensure they could work in various home environments. This testing included evaluating their signal range, response times, and durability to ensure reliable performance when used for everyday tasks.
4. Power Supply Design and Customization:
AC to DC Conversion: One of the biggest challenges was designing a low-cost, efficient power supply for the system. We developed a custom AC to DC converter that efficiently powers the system while minimizing heat generation. This custom integrated circuit (IC) helped keep costs down, but it had limitations in current output. To address this, we optimized the power supply circuit to ensure consistent, stable performance without overheating.
PCB Design Optimization: Once the prototype was successfully tested, we refined the PCB design to ensure compatibility with the client’s 3D molding forms, allowing it to be enclosed in a professional housing that matched the system’s aesthetic and functional requirements.
Cost-Efficiency and Component Selection: To meet the client’s cost-efficiency goals, we carefully selected widely available components that balanced production costs while still ensuring the system worked reliably.
Mobile App Integration: Working closely with the client’s software team, we integrated the system with a mobile app. The app allows users to remotely control their appliances, monitor energy usage, and manage automated tasks like scheduling when devices should be turned on/off.
6. Final Testing and Deployment:
Performance Testing: The final system was put through thorough performance testing. This ensured the system met requirements such as 4G connectivity for remote access, real-time power control, and smooth integration with devices. The system was then deployed, allowing users to retrofit their old appliances into a modern, connected smart home system.
Results:
The final product enabled consumers to seamlessly integrate their existing appliances into a smart home system. Through the mobile app, users can monitor power consumption, control devices remotely, and set automated routines to optimize energy usage and enhance convenience.
Business Impact:
Product Sucess: The Smart Home Automation System drove a 17.7% reduction in power consumption for users, boosting its market appeal.
Production Growth: The product's success enabled the company to produce an additional 5K units' batch to fulfill the demand.
Market Expansion: Increased demand led to a broader reach, scaling the business footprint across 40+ cities.
A future-proof, intuitive design with excellent engineering.
