A smart pressure sensor with an EMC filter in Flamco's Flexcon PA proved to be the solution to a major problem for heating engineers: unplanned service calls without any actual defects.
Two years ago, Flamco wanted to predict the lifespan of expansion vessels in heating systems using a smart pressure sensor application. However, market research revealed that heating technicians had no need for this. They did, however, appear to be looking for ways to reduce unplanned service visits, which were eroding already fragile profit margins.
In an open innovation process, Flamco and the independent sensor supplier Sentech have developed a revolutionary product centered around a smart and extremely accurate pressure sensor: the Flexcon Pressurization Assistant with an automatic refilling unit. The pressure sensor is neither a high-pressure sensor nor a low-pressure sensor.
The advanced pressure monitor is now on the shelves of wholesalers and in the service vans of heating engineers.
Red expansion vessel next to the central heating boiler, usually from Flamco
Most consumers don't realize they have Flamco products in their homes. There's a good chance the red expansion vessel near your central heating boiler is made by Flamco. Flamco develops and manufactures installation products and fittings.
According to Flamco, there's a Flamco expansion vessel in every mechanic's van. It was installers who gave Flamco a revolutionary idea for accurate monitoring of pressure in a heating system.
Flamco introduced the idea as the Flexcon Pressurisation Assistant at the world's largest installation trade fair, ISH 2017 in Frankfurt. Starring a smart pressure sensor from Sentech.
R&D for the installation industry
With its own R&D department, Flamco is working on the world of tomorrow. Its innovations focus on sustainability, efficiency, and connectivity. A sustainable example is the Ontgasser Vacumat Eco, which prevents damage and malfunctions in a heating system.
From the brain of Flamco's R&D department also comes the Flexcon PA. A cost-saving innovation that the installation industry, according to Flamco, has been eagerly awaiting.
Pressure sensor application for expansion tanks
Spiritual fathers Herman Reezigt, R&D team leader, and Erik Hoenderkamp, product developer, talk about sensor development and collaboration with Sentech.
Flamco looked for a way to predict the lifespan of expansion vessels. An expansion vessel compensates for dynamic volume in the heating system with an air cushion. However, the air cushion disappears over the lifespan, and the vessel's membrane wears out.
Reezigt: “An expansion vessel lasts an average of 7 to 10 years. A Flamco vessel lasts even 15 years. With our open attitude towards suppliers and installers, we thought they would benefit from predicting the lifespan of the expansion vessel. With a pressure sensor application, we could warn when an expansion vessel needs replacing.”
Installation industry asks for a solution to unnecessary service calls
When Flamco tested the market, the installation sector turned out to be less eager for such an automatic warning, according to Reezigt. Reezigt: “Most installers replace an expansion vessel every five years, so well within its technical lifespan. We did receive valuable feedback, which allowed us to take a different direction with the same sensor technology.”
According to Reezigt, two out of three unplanned maintenance visits are due to pressure loss in the central heating system. Reezigt states, “Installers and service technicians usually work on the basis of service contracts, in which they are not paid per malfunction. In most cases, a malfunction simply involves refilling the system. Therefore, installers were looking for a solution to reduce unnecessary visits and automatically refill systems.”
Accurate pressure sensor monitors heating system pressure
As product developer, Hoenderkamp coordinated the development in-house. Hoenderkamp: “The Flexcon PA has become an extremely handy tool that very accurately measures the pressure in the system. We have linked an automatic refilling device to this. We supply this optionally with the sensor.”
The sensor's measurement data is used for a mobile app that customers download from the Apple App Store and Google Play Store. “During the initial setup, the device even screens the entire heating system. It learns the installation based on subtle pressure differences during the heating cycle. From this, it calculates the ‘hardness of the installation,’ in other words, the specific behavior,” according to the product developer.
The sensor then uses that number as a reference number throughout its entire lifespan. Hoenderkamp: “The pressure sensor must always remain stable and reliable. It only measures subtle pressure differences. But the device is so smart that it can measure and predict a lot based on that.”
Preventive e-assistant for central heating system installers
The Flexcon PA enables installers to monitor pressure in a heating system long-term and intervene preventively in a timely manner. The data from the app offers technicians a wealth of information.
The app shows, among other things:
- or the expansion vessel is about to fail
- or the safety valve emits water
- whether there is a leak in the system
- if the installation needs to be refilled
The automatic refill unit makes it completely easy for installers and customers. According to Reezigt, installers can organize central heating maintenance much more efficiently with the Flexcon PA.
Product development around sensor technology
Reezigt and Hoenderkamp didn't initially know exactly what requirements to set for the product or which sensor specifications that would lead to. Sentech's help came at the right time.
Hoenderkamp met an account manager from Sentech at a trade show. An appointment at Sentech for a presentation soon followed. Reezigt: “Before we got in touch with Sentech, we thought: how difficult can it be? During that presentation, things came up that we had never thought about. That's when you realize we simply lack that knowledge.” According to Hoenderkamp, Sentech, as an independent sensor supplier, has become “a real knowledge partner” that has guided Flamco.
Hoenderkamp continues: “We developed the housing, interface, electronics, and software around the pressure sensor. The Flexcon PA had to be ready for production for ISH 2017.”
“During this open innovation process, Sentech and Flamco have grown much closer,” says Reezigt. “We saw that Sentech is a company that really knows what it's doing. Despite our position in the market, we are still quite small. You need a flexible yet decisive partner in that case,” according to Reezigt.
Sensor Challenge: Lifespan, Reliability, and Price
Sentech creates a sketch of the sensor solution after the initial contact with Flamco. That sketch was perfected by Hoenderkamp. The main challenges for sensor development were:
- a very narrow constant measurement resolution
- the reliability over a lifespan of at least 15 years
- and the cost
Reezigt: “The wholesaler buys our products and sees our broad program as a major logistical advantage. This allows them to optimally serve installers and construction companies. However, the lowest possible price is a crucial condition for the marketability of the Flexcon PA. Furthermore, the regular adjustment of the scope was a challenge. A partner really needs to be able to handle that!”
Custom sensors from the automotive sector
There was no clear picture yet of what Flamco was looking for. Based on the objectives, I thought about the direction for sensor development. What do I need and where can I get something that fits the concept? When you think about it, you automatically arrive at the automotive industry. There are large volumes, reliable products, and they are ISO TS-certified companies. They understand what quality is.
All specs, all pros and cons were laid out. Over the course of the ride, more and more fell away. I finally ended up in China with a company that makes sensors for automotive coolant systems. Pressure measurement in such a system is almost comparable to a heating system.
Knowledge partner sensor technology
Reezigt: “We have found a reliable knowledge partner in Sentech. Sentech is very flexible. It's nice to notice that Sentech is fully committed. Director Marcel Figge's enthusiasm is also contagious.”
Hoenderkamp adds: “Keeping agreements is very important in such a development. You shouldn't have any surprises leading up to a deadline. The product simply had to be available for the ISH. We had confidence the whole way through that it would turn out fine.”
You can come up with something beautiful, but in the end, you have to be able to sell the product on the market. Moreover, communicating via Bluetooth with an app requires a lot of integration expertise. Despite the high demands, we were still able to create a solid business case.
Fine-tune Electromagnetic Compatibility with an EMC filter
During development, Sentech and Flamco refined the sensor specifications to a Proof of Concept. You still encounter a number of challenges, such as adjusting the EMC sensitivity of the sensor.
Electromagnetic radiation interference caused too much fluctuation in the measurement of subtle pressure differences. We succeeded in minimizing the electromagnetic interference with a redesign of the sensor circuit and additional software filtering. The demo version then passed the test flawlessly.
On to the next sensor development
The Flexcon PA is now on wholesalers“ shelves and making its way to installers and their customers. Reezigt: ”It is suitable for heating systems up to 45 kW. You find these in homes and small offices. However, there is increasing demand for larger systems in bigger buildings."
There are plans for further development towards application in larger installations, but also in hybrid heating systems. “In that regard, there is still much in store for our collaboration with Sentech,” Reezigt concludes.
Innovate to prevent
Flamco started an open innovation process and came up with the best solution with Sentech. Are you also looking for good sensor tools to improve maintenance and service provision? Or are you experiencing a lot of unplanned breakdown visits?
Prevent these directly and explain to us Your challenge Fore!
