Client Need:
A sports technology company developed a prototype of a remote sensor that provided data to an Android-based ‘head unit’ via Bluetooth Low Energy (BLE). They sought to transition their early prototype sensor, built on Arduino, to a production-ready version for integration into their athletic training system. Their in-house hardware developer had departed mid-project, leaving an incomplete hardware design and no firmware.
Wolff Electronic Design Solution:
Wolff Electronic Design was brought in to complete the project, beginning with formalizing product requirements from a preliminary feature list. These were transformed into a comprehensive and testable specification, setting the foundation for both hardware and firmware development. Wolff Electronic Design also contributed to the development of the Android-based head unit.
Key Contributions
Hardware Development:
- Reviewed and identified critical flaws in the client’s initial hardware design.
- Modified the design to correct issues and fabricated new prototype hardware.
- Integrated key components including:
- Nordic Semiconductor nRF52 BLE processor
- Accelerometer
- Lithium-Ion battery, charger, and fuel gauge
Firmware Engineering:
- Developed and tested firmware on development kits prior to hardware availability.
- Implemented a custom BLE service for control and data transmission.
- Integrated and debugged firmware on the revised prototype hardware.
- Implemented power-saving modes
- Optimized power consumption for long battery life
- Added over-the-air firmware update capability over BLE
- Executed formal verification testing based on a custom test plan developed for this project.
Machine Learning Integration:
- Designed and implemented firmware support for the client’s machine learning algorithm (mathematical model).
- Contributed to the algorithm design. The client’s prototype had never incorporated the algorithm in the microprocessor, so a major portion of the real-world implementation was developed from scratch.
- Implemented the capability to obtain real-time accelerometer data used to evaluate and tune the algorithm’s performance.
Android Head Unit Development:
- Built low-level driver interfaces using Android NDK.
- Conducted hardware design reviews of the Android-based head unit.
Outcome:
Wolff Electronic Design delivered a fully functional sensor system with integrated firmware, robust hardware, and Android connectivity over BLE, significantly advancing the client’s product toward commercial readiness.
Skills/Technologies:
Android NDK, Core Bluetooth, Firmware Programming, Electronic Design, Test Planning, Requirements Specification, Functional Testing, Android App Development, Project Management, Project Scheduling
