Problem
Existing site builds used a loose mix of valves, flow meters and solenoids creating long install times, multiple leak paths, and inconsistent diagnostics.
Approach
- Designed a cast body that accepts the flow sensor, purge/test-point, and isolation valves on a single spine.
- Created a compact IP65 electronics pod with strain relief and keyed connectors for safe swaps.
- Optimised casting draft, parting lines, and machining pads for low-cost repeatability.
- Ran DFMEA to drive sealing strategy and fault-tolerant manual overrides.
Result
Assembly time reduced by ~18%, leak points reduced, and field diagnostics simplified with an accessible test valve and clear labelling. The architecture supports multiple actuator options without body changes.
