CASE STUDY SNAPSHOT
Customer : A US-based startup focused on IoT solutions for industrial automation and smart infrastructureSize : <50
Project vertical : Industrial and IoT
Challenge : Cost-effective, Rapid Product Development for a remote data acquisition system using the eStorm-L1 platform, compliant with industrial standards
Solution : eStorm-L1-powered IoT gateway with RAPIDSEA and Flint IDE for accelerated development
Services Availed : Turnkey Product Engineering Services, Embedded Software Development, IoT System Integration, RAPIDSEA, Flint IDE
Tools and Technologies :
- Hardware: Ready to Deploy eStorm-L1 Kit (NXP Kinetis KL25, ARM Cortex-M0+)
- Programming Languages: C
- Software Development: Flint IDE, RAPIDSEA Suite, GCC Toolchain
- Frameworks: RAPIDSEA (drivers, middleware, protocol stacks)
- Protocols: HTTP, MQTT, UART, RS232/RS485
INTRODUCTION
A US-based startup specializing in IoT solutions for industrial automation approached Embien to develop a proof-of-concept (PoC) for a remote data acquisition system. The goal was to create a scalable, low-cost IoT gateway to collect and transmit sensor data to a cloud server for real-time analytics. Leveraging the eStorm-L1 platform, Embien did rapid product development, enabling the customer to validate their concept and accelerate time-to-market.
CHALLENGE
The customer required a functional prototype within a tight timeline to demonstrate their IoT solution to stakeholders. Key challenges included:
- Cost and Scalability: The solution needed to be affordable for mass deployment in industrial settings while supporting diverse applications like M2M and IoT.
- Rapid Product Development: The prototype had to be developed quickly to meet stakeholder deadlines, requiring ready-to-use hardware and software components.
- Interoperability: The system needed to interface with multiple communication protocols (UART, RS232/RS485, HTTP, MQTT) and integrate with cloud infrastructure.
SOLUTION
The remote data acquisition system was built around Embien's eStorm-L1, an advanced mbed-enabled IoT gateway powered by the NXP Kinetis KL25 (ARM Cortex-M0+) microcontroller. This versatile platform provides comprehensive connectivity options including multiple analog/digital I/Os, industrial-grade RS232/RS485 interfaces, high-speed USB ports, and optional GSM cellular connectivity, making it an ideal solution for rapid IoT prototyping and development of connected systems.
Remote Data Acquisition System Development
Embien's experienced turnkey product development team successfully executed the following key components:
Remote Data Acquisition System Hardware
Strategically utilized the Ready to Deploy eStorm-L1 Kit, a thoroughly pre-qualified Commercial Off-The-Shelf (COTS) platform, which eliminated the time-consuming need for custom hardware design and validation. The module's sophisticated built-in debug interface and extensive expansion options enabled immediate deployment and testing. The hardware architecture was optimized for reliable data acquisition in industrial environments.
Remote Data Acquisition System
Software Tools
Extensively leveraged the comprehensive RAPIDSEA development suite, which provided robust driver modules (I2C, SPI, UART, Ethernet) and industrial-grade middleware components (TCP/IP stack, MQTT client). The intuitive Flint IDE enabled efficient no-code configuration capabilities, allowing for rapid system setup and streamlined implementation of complex business logic. The software framework ensured reliable operation and easy maintenance.
Firmware Development
Engineered a sophisticated C-based application specifically designed to collect high-frequency sensor data through multiple interfaces including UART and RS232/RS485 protocols. The application efficiently processed incoming data streams, implemented error checking algorithms, and securely transmitted processed information to cloud servers using industry-standard HTTP/MQTT protocols. Unique device identifiers and authentication mechanisms were implemented to ensure secure and reliable server interactions.
Power Optimization
A complete power consumption profile is done for each peripheral in the system. Careful measurements are made and resources used sparingly. To avoid peripherals consuming power, they are switched off usually and on only during the time being used. GSM Modem, the most power-hungry component, is powered only when communicating with the server. Data batching is also done to reduce overall on time. LCD Backlight is switched on only when the user is using the UI. Further the processor is made to run in active mode only when it is time for data acquisition. During other times it remains in low power sleep mode consuming very low current. But the responsiveness of the system is not compromised, and the user can view the current data on character LCD upon pressing any of the navigation keys at any instant.
Cloud Integration
Meticulously configured the system to seamlessly push acquired data to a centralized server through authenticated web requests. This enabled comprehensive real-time analytics, continuous system monitoring, and data visualization capabilities. The cloud architecture was designed to handle high-volume data ingestion while maintaining data integrity.
Testing
Conducted extensive functional and stress testing procedures to thoroughly validate all aspects of data acquisition, communication reliability, and cloud integration. This included testing under various network conditions, validating error recovery mechanisms, and ensuring consistent performance under peak loads. Comprehensive test reports were generated to document system behavior and performance metrics.
The fully functional prototype was successfully delivered within a compressed timeline of just a few weeks, meeting the customer's aggressive development schedule. The rapid product development demonstrated reliable operation during extended trial runs, consistently maintaining data accuracy and transmission reliability. Embien's team provided detailed technical documentation covering system architecture, configuration procedures, and troubleshooting guidelines. Additionally, comprehensive support was extended during stakeholder demonstrations to ensure smooth presentation of the system's capabilities and features. The delivered solution established a robust foundation for future scalability and feature enhancements while maintaining operational simplicity for end users.
BENEFITS
- Cost-Effective Design: Leveraged the low-cost eStorm-L1 module, reducing development expenses.
- Rapid Prototyping: RAPIDSEA and Flint IDE accelerated development, enabling a functional PoC in weeks.
- Scalability: The eStorm-L1 platform’s flexibility supports diverse IoT applications, from M2M to remote monitoring.
- Interoperability: Supported multiple protocols (HTTP, MQTT, UART, RS232/RS485) for seamless integration.
- Stakeholder Validation: The reliable prototype facilitated successful concept validation with stakeholders.
CONCLUSION
The eStorm-L1-based remote data acquisition system enabled the customer to demonstrate a robust IoT solution to stakeholders, paving the way for further development and deployment. Embien’s expertise in rapid product development, combined with the eStorm-L1 platform, RAPIDSEA suite, and Flint IDE, delivered a cost-effective, scalable solution that met stringent timelines. This success underscores Embien’s capability to accelerate IoT product development for industrial applications.
