Industrial Design
The product consists of an ozone generating component and a delivery system. The ozone generator is relatively traditional with the exception that we moved away from using displacement style air pumps and decided to use a radial fan for creating the large airflow required. The fan was developed making extensive use of CFD to optimise the fan for performance, size and noise. CFD was also used to optimise the airflow around the ozone generators for maximum ozone generation and heat transfer for cooling.
The delivery system is the key to the product and a highly iterative development process, with multiple prototypes being manufactured, resulted in a 100% disinfecting rate. The customer wanted to protect the IP and the design was done in such a way that it is almost impossible to reverse engineer the design or principles it is based upon.
Electronic Development
The controller uses water flow as a main sense to activate the unit. PID control is used to control all the internal systems, including ozone generator and fan, relative to water flow. The system also uses removable storage to log all usage parameters of the unit and uses the same system to upgrade firmware. Careful attention had to be paid to the interference of the HV unit to the controller board.
Industrial Design
Upon completion of the elements, air unit, controller board and ozone unit the product was designed taking care that the ozone is contained and that the unit is splash proof as it will be installed in kitchen environments.
Prototyping
Fully working prototypes were built using traditional methods. All seals were made with aluminium compression moulds manufactured at Skeg.
All seals are prototyped this way as traditional prototyping methods are not of high enough quality.
The dispensing unit was manufactured, assembled and over-moulded with our in-house low pressure moulding technology.
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