CASE STUDY SNAPSHOT
Customer : Industrial Device OEMSize : < 50
Project vertical : Industrial IoT (IIoT) & Automation
Challenge : Developing ultra-long-range (>1500 ft), battery-powered sensors with high security and FCC-compliant communication.
Solution : A custom Sub-1GHz wireless ecosystem featuring multi-type sensors and a 5G-enabled edge gateway.
Services & Products Availed : Product engineering services, Hardware Design, Embedded Firmware, Custom Protocol Development, Cloud Integration, Secure Updates
Tools and Technologies :
- Key Hardware: TI CC1314R10 (Sensors), NXP LPC54628 (Gateway)
- Connectivity: Sub-1Ghz, 5G Modem and Ethernet
- Software Development: C/C++, TI-RTOS, FreeRTOS
- Security: AES256
- Protocols: FHSS, Web Servers, Sub-1GHz Radio
Introduction
Our client, a prominent industrial OEM, sought to revolutionize their field monitoring capabilities. They required a versatile suite of wireless sensors capable of measuring temperature, pressure, and digital inputs across expansive industrial environments. The goal was a robust, secure, and long-range system that could transition data from the "edge" to the cloud seamlessly.
Challenge
The project presented a trifecta of engineering hurdles. First, the communication range had to exceed 1500 feet in potentially noisy industrial environments, making standard protocols like Zigbee or Bluetooth insufficient. Second, the power constraints were extreme: the devices needed to operate for at least two years on just two AAA batteries while maintaining constant security. Third, regulatory compliance was non-negotiable. To operate in the unlicensed bands, the system needed an intelligent frequency management strategy to satisfy FCC requirements while protecting data against sophisticated cyber threats via high-grade encryption.
Solution
Architectural Foundation: Sub-1GHz and the TI CC1314R10
To meet the 1500-foot range requirement, Embien opted for a Sub-1GHz architecture. Unlike 2.4 GHz signals, Sub-1GHz waves offer superior penetration through concrete walls and industrial machinery. We selected the TI CC1314R10 as the core microcontroller for the sensor nodes. This chip provides an excellent balance of high-performance radio capabilities and ultra-low power consumption, essential for the long-term battery life the OEM demanded.
Engineering a Custom Secure Protocol
Early in the evaluation, it became clear that standard off-the-shelf protocols were too "chatty" for the power budget or lacked the specific security features required. Embien developed a proprietary lightweight wireless protocol optimized for industrial telemetry.
To ensure the system was "Secure by Design," we implemented AES256 encryption for every packet. To prevent replay attacks, session keys are dynamically negotiated and changed for every communication session. Furthermore, to comply with FCC regulations and mitigate interference, we integrated a Frequency Hopping Spread Spectrum (FHSS) technique. This allows the devices to "hop" across frequencies, ensuring that no single band is over-utilized and providing inherent immunity to narrowband jamming.
Hardware Versatility and Power Optimization
The sensor hardware was designed with a modular Analog Front End (AFE). By creating a unified communication interface for the ADC, we allowed the same base PCB to be populated with different sensor components, be it a thermocouple, pressure transducer, or digital input circuit. This significantly reduced manufacturing complexity for the client.
To achieve the 2-year battery life, we implemented a sophisticated power management state machine. The sensors spend 99% of their time in a "Deep Sleep" mode, drawing only micro-amps. The custom protocol ensures that when the device "wakes up," the handshake and data transmission occur in milliseconds before the device returns to sleep.
The Intelligent Edge Gateway
The backbone of the system is the Wireless Gateway, powered by the NXP LPC54628 and the TI CC1314R10 for radio management. This gateway serves as the bridge between the Sub-1GHz sensor network and the wider internet.
Connectivity: We provided high-speed backhaul through a 5G modem and integrated Ethernet.
Edge Configuration: To simplify field deployment, the gateway hosts an internal web server. Technicians can configure the network locally via a browser or remotely via the cloud.
Maintenance: Both the gateway and the sensors support Firmware Over-The-Air (FOTA) updates, allowing the OEM to push security patches or new features to thousands of devices simultaneously without manual intervention.
Benefits
Unmatched Range:Stable communication exceeding 1500 ft, even in dense industrial settings.
Longevity:Proprietary power-saving logic extends battery life to 2+ years on standard AAA cells.
Military-Grade Security:AES256 encryption with dynamic session keys ensures data integrity and privacy.
Rapid Time-to-Market:The entire multi-node ecosystem was moved from concept to production-ready in just 6 months.
Seamless Scalability:Modular AFE and FOTA capabilities allow the client to expand their product line without redesigning the core architecture.
Conclusion
Embien’s expertise in low-power wireless design and high-security protocols enabled the industrial OEM to launch a market-leading sensor suite that outpaces competitors in range and reliability. By balancing the complexities of FCC compliance with the need for a simplified user experience, we delivered a system that is as robust as it is innovative. Whether you are looking to monitor a single factory floor or a vast agricultural field, Embien has the tools to make your data mobile.
Ready to build your own custom wireless ecosystem? Contact Embien today to discuss your IoT roadmap.