Projektausgangslage und Herausforderungen
Our client, an innovative manufacturer of electric water sports equipment, required a customised firmware solution for its ESP32-based vehicle controllers. The company had already developed successful hardware but faced the complex task of implementing reliable and secure embedded software that meets both the demanding requirements of water sports and the high safety standards of the e-mobility sector.
The technical requirements were exceptionally demanding: the system had to ensure real-time communication with VESC motor controllers, manage Bluetooth connections to mobile devices simultaneously, implement critical safety functions, and operate reliably in a saltwater environment with extreme temperature fluctuations. Additionally, the firmware was to support over-the-air updates and provide a modular architecture for future product variants.
Dual-Controller Architektur
After a thorough analysis of the requirements, we developed an innovative dual-controller architecture consisting of two specialised ESP32 systems: the OCEAN Controller as the main control unit and the OCEAN Remote as a wireless remote control. This division allowed us to optimise each system for its specific tasks while simultaneously reducing complexity.
The OCEAN Controller acts as the central nervous system of the vehicle and manages all critical functions. We implemented a high-performance communication layer that communicates simultaneously with VESC motor controllers via UART and with battery management systems via CAN bus. Particularly challenging was the development of the real-time scheduler, which ensures that safety-critical functions such as emergency shutdowns are executed within microseconds.
The OCEAN Remote has been designed as an ergonomic remote control that allows for intuitive operation even under challenging conditions. We developed an adaptive Bluetooth protocol that maintains a stable connection even in the presence of electromagnetic interference or over long distances. The system implements intelligent reconnection algorithms and fallback mechanisms that ensure safety even in the event of temporary connection interruptions.
Sicherheit als oberste Priorität
As the firmware is used in safety-critical applications, we developed a multi-layered security concept that goes far beyond standard embedded systems. At its core is an intelligent monitoring system that continuously monitors all critical parameters such as battery voltage, motor temperature, and system load.
Our water contact detection system, specially developed for e-surfboards, is particularly innovative. The system uses a combination of acceleration sensors, pressure sensors, and electrical conductivity measurements to reliably detect whether the vehicle is in the water. In the event of a loss of water contact, the motor is switched off within milliseconds to prevent injuries.
The firmware also implements a robust watchdog system with multiple monitoring levels. In addition to the hardware watchdog of the ESP32, we developed a software-based task monitor that oversees the proper execution of all critical processes and automatically establishes a safe system state in the event of anomalies.
Drahtlose Kommunikation und Konnektivität
One of the biggest technical challenges was the development of a reliable wireless communication system that works even under extreme conditions. We implemented an adaptive Bluetooth Low Energy protocol that automatically adjusts to the environmental conditions and dynamically optimises the transmission parameters.
For the Over-the-Air update functionality, we developed a secure and robust system that ensures the device remains operational even during connection interruptions during the update process. The system uses a dual-boot architecture with automatic rollback for failed updates and cryptographic signature verification to prevent tampering.
We are particularly proud of the implementation of the mesh networking feature, which allows multiple vehicles to connect and exchange information. This opens up new possibilities for group activities and enables the sharing of safety information between vehicles.
Performance-Optimierung und Ressourcenmanagement
The development of high-performance firmware on a resource-constrained ESP32 system required innovative optimisation approaches. We implemented an intelligent power management system that minimises the energy consumption of the controller while ensuring full functionality.
By using FreeRTOS, we were able to implement a deterministic multitasking system that operates reliably even under high load. Critical tasks such as motor control are given the highest priority, while less time-critical functions like Bluetooth communication are processed at lower priority levels.
For data storage, we developed an efficient SPIFFS-based file system that reliably stores configuration data, logs, and telemetry data. The system implements wear leveling and error correction to maximise the lifespan of the flash memory.
Entwicklungsumgebung und Qualitätssicherung
To meet the high quality standards, we established a professional development environment based on PlatformIO. We implemented comprehensive unit tests for all critical functions and developed a hardware-in-the-loop testing system that enables automated tests under realistic conditions.
The firmware undergoes a rigorous CI/CD process with automated builds, tests, and code quality checks. Each change is tested in a simulated environment before being released for hardware testing. This ensures high code quality and reduces the risk of errors in production.
Projektergebnis und Kundenerfolg
The developed firmware has exceeded our customer's expectations and enabled the company to successfully launch its product line. The system is now running in over 5,000 vehicles worldwide and has achieved a failure rate of less than 0.1%.
Particularly impressive is the reliability of the Over-the-Air update system: over 95% of all updates are successfully carried out without user intervention, which has significantly reduced maintenance costs. The modular architecture also enabled our client to quickly develop new product variants and considerably shorten the time-to-market.
The firmware has proven to be so robust and versatile that it is now also being used in other application areas such as e-scooters and industrial IoT systems. This demonstrates the quality and adaptability of our embedded development.
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