Expert firmware maintenance enhancing industrial IoT reliability.

Industrial IoT deployments face challenges in maintaining reliability, security, and power efficiency as devices scale. Our IoT Device Firmware Optimization service directly addresses these critical needs, ensuring your devices remain secure, efficient, and fully functional long after initial deployment.

The client manages two distinct industrial IoT products deployed extensively across global markets. With over 1,500 units of one product model and new model launched in 2023, both required ongoing firmware updates for enhanced performance, new feature integrations, battery optimization, and security enhancements.

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Solution Highlights

Our team utilized the powerful Cypress PSoC 6 microcontrollers and FreeRTOS for real-time reliability. Communication capabilities spanned Bluetooth Low Energy (BLE), UART, SPI, I2C, cellular LTE-M/NB-IoT via Quectel BG96 and u-blox SARA R4 modules, and RTK-capable GPS using u-blox NEO-M8P. Firmware updates leveraged secure protocols (MQTT/S, HTTP/S), enabling seamless remote deployments.

Key deliverables included:

• Frequent firmware updates (quarterly or monthly)
• Power optimization to enhance battery life
• Rapid response capability for urgent field updates

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Before IoT Device Firmware Optimization, managing frequent firmware updates across our deployed IoT devices was challenging. Maintaining battery life, introducing new features, and quickly addressing security vulnerabilities was difficult, particularly for our newer product line that required monthly updates. Ensuring device reliability and minimal downtime while scaling deployment was a critical pain point.

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Our approach began by closely collaborating with the client’s internal product teams to define and prioritize firmware enhancements. Leveraging Cypress PSoC 6 microcontrollers and FreeRTOS, we optimized firmware for power efficiency, achieving  extended battery life. Cellular connectivity enhancements via Quectel BG96 and u-blox SARA R4 modules ensured stable LTE-M/NB-IoT communication.

We implemented secure OTA firmware updates using robust MQTT/S and HTTP/S protocols, enabling seamless deployments across diverse geographic locations. Each firmware iteration addressed bug fixes, security patches, feature improvements, and significant enhancements to peripheral communication (BLE, UART, SPI, I2C). Rapid response capability was also integrated, supporting urgent customer-driven updates within tight timelines.

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Value add

Our IoT Device Firmware Optimization delivered significant return on investment by minimizing field downtime and extending the operational lifespan of deployed devices. Scalable firmware solutions ensured seamless integration of new functionalities, directly impacting operational efficiency and customer satisfaction. Our sustained support infrastructure became a strategic asset, enabling confident global deployment and future product scalability.

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