Retractable Pool Cover
Overview
Shortly after joining Dekobo, I was assigned to resolve a critical reliability issue affecting the newly introduced E-STAR retractable pool cover system. Several of the first installed units experienced failures of the drive mechanism responsible for moving the retractable structure, preventing the covers from operating reliably.
My role was to investigate the root cause of the failures, develop a permanent engineering solution that could be retrofitted to existing installations as well as incorporated into future production, and update the mechanical design accordingly.
Project Development
The E-STAR system used a Bosch drive motor coupled through a timing belt transmission to drive the wheels supporting the retractable structure. Customers reported that the covers failed to move and produced abnormal noises during operation.
I began by reviewing the existing CAD models and identified that the transmission design did not include any mechanism for adjusting or maintaining timing belt tension. During field inspections, technicians confirmed that the timing belts had suffered severe tooth wear and damage, consistent with insufficient belt tension under operating load.
Further investigation showed that the original prototype had been tested without the pool cover slats installed. While the unloaded transmission operated satisfactorily during factory testing, the additional load of the complete assembly exceeded the capability of the untensioned belt drive.
Transmission Redesign
To permanently resolve the issue, I redesigned the transmission assembly by incorporating an adjustable timing belt tensioner. The solution maintained the required belt tension while remaining compatible with both new production units and already installed pool covers.
One of the main engineering challenges was the limited installation space, particularly on the Ibiza E-STAR model, where the transmission compartment offered very little room for additional components. The redesigned assembly therefore had to remain compact while allowing straightforward adjustment and maintenance.
Production Improvements
In addition to the transmission redesign, I designed a custom protective cover for the Bosch drive motor, which was manufactured in-house using 3D printing.
Following implementation, the redesigned transmission successfully resolved the reliability issues and was adopted as the standard solution for future E-STAR production while also providing a retrofit solution for previously installed systems.
Outcome
The project demonstrated the importance of designing for real operating conditions and validating mechanical systems under representative loads. By identifying the root cause of the field failures and developing a retrofit-compatible solution, the reliability of the E-STAR transmission system was successfully restored.