A self-powered controller upgrade.
A water heater with built-in connectivity that requires no plug-in or installation changes.
5x Smarter
100% Self-powered control board
U.S. Patent awarded in 2023
Designed for connectivity
Energy-harvesting control system
The controller converts heat from the thermopile into electricity, removing the need for external wiring or power supplies.
Smart diagnostics with low power draw
Embedded firmware manages limited energy efficiently while enabling remote monitoring and smart features.
Active anode modulation for corrosion protection
Control logic adjusts the electrical current to the anode, helping reduce corrosion and extend tank life.
UL-certified electronics for hot wet environments
All components meet UL safety standards for reliable operation and compliance.
Results that make a difference
No plug no problem
We harvested energy from the thermopile to eliminate external wiring, making installation simple and electrician-free.
Connectivity without wiring
We enabled connectivity features and diagnostics in a self-powered system, giving users visibility into performance without changing their experience.
Longer life by design
We added firmware logic to modulate the anode to help limit corrosion, extend tank life and reduce the risk of failure over time.
Project Overview
A better way to power smart
A.O. Smith wanted to add connectivity to its gas water heaters without requiring an electrician or changing the standard install process.
Our solution modernized the product without changing the platform, installation steps or safety profile. It also made the heater five times smarter, enabling:
- Remote diagnostics
- Connectivity
- Corrosion control
- Low-power operation
- Long-term reliability
The result was a patented upgrade that brings smart control to a trusted platform, with no plug required.
The challenge
No outlet. No compromise.
Gas water heaters rely on a standing pilot light for ignition but do not have an electrical connection. That made it difficult to add features like performance tracking, diagnostics or mobile controls. Installing external power would require a licensed electrician and increase installation complexity.
A.O. Smith needed a connected solution that could fit within the existing footprint. There could be no power cord, no added installation requirements, and no compromise on safety.
Our approach
Design for the environment
We viewed the absence of power not as a limitation, but as a design opportunity. We built a custom control board that operates entirely on energy harvested from the heater’s thermopile. This provided a steady power source without requiring external wiring.
From there, we developed embedded firmware to manage energy use, support wireless connectivity, and provide live diagnostic feedback. We also added anode control logic to reduce corrosion and extend tank life. Every part of the design was built to meet UL safety requirements for high-heat, high-moisture environments.
Good design is taking a real-world constraint and transforming it into a longevity solution.
That’s what we did for A.O. Smith.
That’s our goal for all clients.
Skills & Equipment Used
Industrial product design
Electrical engineering design
- Energy harvesting and low-power circuit design
- Custom power management architecture
- Compact board layout and power routing
- Oscilloscopes, multimeters, simulation tools
Mechanical engineering
Firmware development
- Embedded systems and smart diagnostics
- Connectivity for low-power devices
- Anode control logic and power regulation
- C/C++, hardware abstraction layers, debug tools
Software product development
Product concept development
Let’s talk about your next smart system.