Client Overview
A multinational medical devices manufacturer was interested in enhancing the safety, compliance, and performance of their life-support equipment by means of upgrading the embedded systems in their control units. The devices were used in risk-prone areas, like in the ICUs and in the emergency response units, where a matter of milliseconds could mean saving lives. But the legacy systems that the client used did not provide real-time fail-safes, had an outdated firmware architecture, and exhibited a tendency to detect errors slowly, creating additional risks to patient safety and adding to support costs.
By partnering with eInnosys, the company was able to modernize its firmware, produce powerful real-time processing and device reliability and safety. The result was a 70 percent decrease in malfunction reports on the devices, with real-time processing increasing by 60 percent, guaranteeing superior performance in critical cases.
About the Company
Key Challenges
Slow Processing in Legacy Firmware
The most important life-support functions were delayed when multithreaded operations were involved and when the system was under peak load.
No Real-Time Error Reporting
The failures and faults were identified manually once their symptoms were observed, which resulted in excessive support turnaround times.
Firmware Bugs & Lack of Update Mechanism
Updates to all firmware had to be performed with physical access to the devices, which caused compliance bottlenecks and recall risks.
Poor Sensor Integration
The sensors provided by various manufacturers failed to work together, thus leading to unreliable and inconsistent real-time monitoring.
Our Embedded Solutions
Firmware Optimisation for Real-Time OS (RTOS)
We have reimplemented the firmware of the devices using FreeRTOS and Zephyr that enables us to predict the execution of tasks and processing of real-time interrupts in a high processing load situation.
Self-Diagnostics & Failsafe Mechanisms
Self tests, watchdog timers, and memory integrity checks were introduced as built-in features that would automatically restore the system before the end user would even know that there was a failure.
Over-the-Air (OTA) Firmware Updates
Enabled secure, encrypted firmware updates over Wi-Fi and BLE with rollback support, allowing compliance patches to be deployed without disruption.
Unified Sensor Communication Protocol
Include a hardware abstraction layer (HAL) so that communication is standardised between I2C, SPI, and UART sensors to achieve consistent real-time telemetry.
Tech Stack
Microcontrollers : STM32, PIC32
RTOS : FreeRTOS, Zephyr
Languages : C, Embedded C++, Assembly
Connectivity : BLE, LoRaWAN, Wi-Fi
Diagnostics : JTAG, I2C/SPI Debug Tools
Update Protocols : MQTT, HTTPS for OTA
Business Impact
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