When a father and son approached us at Henway Engineering, they came with a clear vision: they wanted to add an automatic motorized canopy controller that could operate their canopy products with the push of a button. While they were knowledgeable about mechanics, they needed a team to handle the electrical engineering side of the project.
After choosing Henway Engineering as their partner, we discussed their desired user experience and electrical engineering needs. They wanted—a simple, intuitive user experience that didn’t compromise reliability. We took the conversation deeper, asking about preferences for device functionality, user experience, production cost estimates, size, production line testing, and more.
The requirements we all came up with included a system that used two PCBs. One PCB would contain the controller housing the up/down buttons, feedback LEDs, microcontroller, power connections, and more. The other PCB at the canopy would incorporate low-cost hall sensors and a magnet as the motor encoder, enabling the canopy to operate without traditional limit switches.
There were concerns about the unit creeping out of calibration without limit switches, so we quickly prototyped this aspect of the project while we developed the rest of the system to save time.
The results were awesome. After 2,300 hours of continuous testing, the canopy performed very well, maintaining its calibration. To be extra safe, we also incorporated current-limiting circuitry that protects the motor and software that adapts the soft limits if the motor stalls.
The picture shows the motor encoder PCB with connections for the motor and a cable harness that leads back to the control box.
The PCBs are currently in production, and the customer is pleased with the design. We’re currently discussing a quote for remote control operation.
This project is just one example of how Henway Engineering transforms ideas into reality, offering end-to-end custom electronics solutions that help businesses innovate and grow. Whether you’re a small startup or an established company, we’re here to help you bring your visions to life with precision and reliability. Contact us.