IoT connected smart appliances
The Brief
Our client could see that with IoT, there was an opportunity to take a fresh approach to their product business model and their client relationships. To achieve this, they required a suite of connected devices with a smart network management solution that could connect a large number of appliances with each other, and a central appliance serving as a cellular gateway to the cloud.
A complete end-to-end IoT solution was required, including:
- Hardware and software for the embedded gateway and local network units.
- Cloud solution, including payment and App interfaces.
- Web-based dashboard UIs for admin and maintenance.
- Support for new product introduction (NPI) through strict conformance and safety testing and into volume production.
The client’s funding was dependent on the early delivery of a viable demonstrator installed in a public space, showcasing many features of the final product.
The Solution
Our top priority was to quickly provide a reliable representation of the final product to reassure financial backers. To achieve this, we used carefully selected third-party hardware. This allowed us to begin Agile development and testing of the final software solution from the start, with an early delivery that met the demo requirements. At the same time, we started the specification and development of the product electronics.
Later in the project, the software development simply transferred to the Fen-developed product electronics, with software that was pre-qualified on the third-party hardware.
We created a central cloud repository for live and historical data, as well as for control of all appliances on the network. The associated applications and databases enabled the implementation of the business rules and conditions of use.
We provided a REST API for third-party app developers. Using the same API, we developed a set of secure multi-level access web dashboards, which allowed site, multi-site, and global access to all devices on the network.
We developed a suite of electronics modules for site installation, capable of adapting to different AC mains scenarios. These modules self-organize around a Fen-developed cellular gateway, finding the optimal RF path through the mesh network and self-healing in the event of communication outages.
We worked closely with the client on the New Product Introduction. The various AC mains devices were required to meet international conformance standards, including VDE. We supported this activity through to completion.
We defined and commissioned the production test process, designing and delivering bespoke test equipment for that purpose. In addition, we provided training for the client’s production line technicians.
We completed the integration of the production test process with the back-end cloud databases in preparation for commissioning products in the field.
We architected the complete end-to-end IoT solution, including recommending key technologies for both cellular and local area communications.
An infrastructure was created that enabled the client to evolve product requirements and specification details throughout the development life cycle.
The Agile approach to development complimented the client’s need to develop their product narrative through interaction with their end customers during prototyping and field trial phases.
The client had aggressive product hardware BOM cost targets. Appropriate system architecture and specification ensured sufficient freedom, in key component design choices, to meet these targets.
Marrying multi-phase AC mains power electronics with sensitive low voltage processor and RF circuitry presented a design challenge. We used our experience in this field to design a modular solution that supported several different product variants.
With Agile developments of this type, Fen uses a test-driven development approach. This ensures that the addition of new features and resolution of bugs undergo a full system regression test as part of the development process.
During the delivery of the project, we were able to support the client in taking ownership of long-term software responsibility, as they recruited their in-house software development team. This included the provision of client engineer training and support for the introduction of a number of secure billing systems into the product offering.