The development of Internet of Things (IoT) technology has revolutionized how we connect with the world around us. From smart homes to advanced industrial systems, IoT devices are becoming an integral part of our daily lives. For IoT engineers, creating IoT hardware is fascinating yet challenging. As said Steve Mollenkopf, Qualcomm’s CEO – “The Internet of Everything is a more complex ecosystem than anything we’ve seen before. Hardware, software and connectivity must all work together seamlessly.”
This article will discuss the essential stages of the IoT hardware development process, from conceptual design through prototype building to testing and validation. It will also present best practices and the latest tools and technologies that help engineers create innovative and durable IoT solutions.
An IoT (Internet of Things) device is an electronic device that is connected to the internet and can collect, transmit and receive data. Thanks to this, IoT devices can interact with each other and with other systems, creating intelligent and automated environments.
The differences between IoT devices and traditional electronic devices are significant. Conventional electronic devices usually lack the capability to connect to the internet or communicate with other devices. IoT devices, on the other hand, are designed for network integration and can exchange data and collaborate with other devices and systems in an automated manner. Moreover, IoT devices often include advanced data processing functions that allow them to analyze collected information and make real-time decisions.
At its core, IoT hardware encompasses all the physical devices and components that enable connectivity, data collection and processing. These include:
Power Management: Managing power efficiently is crucial, especially for remote or battery-powered IoT devices. Back in 2020, the average energy consumption by IoT devices was 50mW, whereas this year it is already down to 37mW. Clearly, there is a downward trend in this area, so choosing low-power components like Texas Instruments MSP430 and Nordic Semiconductor nRF52 series microcontrollers can make a big difference. The ESP32, with its deep sleep modes, is also a good choice. Based on our experiences efficient sensors such as the Bosch BME280 for environmental sensing and the Texas Instruments HDC1080 for humidity and temperature measurement, along with low-power communication modules like the LoRa SX1276 and Nordic nRF52840, help conserve energy.
Using energy harvesting techniques can further extend the lifespan of IoT devices. Solar power is a great option, managed effectively with the SPV1050 by STMicroelectronics. Kinetic energy harvesting, used in EnOcean’s technology, is common in building automation and smart home products. On the other hand, thermal energy harvesting can utilize devices like Texas Instruments’ bq25570, which harness energy from temperature differences.
Connectivity: The number of connected IoT devices worldwide reached 28.4 billion last year, representing an increase of over 39% compared to 2020. Selecting the right communication protocol is vital for IoT devices. Wi-Fi is best for high data rates and real-time communication, with the ESP8266 and ESP32 modules being popular options but for short-range, low-power needs, Bluetooth Low Energy (BLE) with the Nordic nRF52840 is ideal. Zigbee, such as the XBee Zigbee module by Digi International, works well for low-power, low-data rate applications like home automation. Alternatively, for long-range and low-power applications like smart agriculture, LoRaWAN with the Semtech SX1276 module is suitable.
Security: Security is paramount as IoT devices are vulnerable to cyber threats. According to implementing AES encryption, with secure key storage provided by devices like the ATECC608A by Microchip is essential. In contrast, secure boot mechanisms, such as those in NXP i.MX6 microcontrollers, ensure only authenticated software runs on the device and over-the-air (OTA) updates are crucial for keeping devices secure with the latest patches.
Scalability: Scalability ensures the IoT system can grow and handle more devices without performance issues. Designing hardware with modularity in mind allows for easy upgrades. However, using scalable cloud services like AWS IoT Core or Azure IoT Hub helps manage increased device counts and data loads effectively.
Compliance and Standards: Meeting industry standards ensures IoT devices are interoperable and legally compliant. Important certifications include ISO/IEC 27001 for Information Security Management and ISO/IEC 20000 for IT Service Management. Adhering to IEEE 802.11 for Wi-Fi and IEEE 802.15.4 for low-rate wireless personal area networks also is essential. Additionally, obtaining CE Marking for devices sold in the European Economic Area, FCC Certification for those sold in the United States and RoHS Compliance to restrict hazardous substances is crucial.
Prototyping and development in IoT hardware are essential stages that ensure devices are functional, reliable, and meet the necessary performance standards. The key steps involved are as follows:
Conceptual Design: Begins with a comprehensive understanding of requirements and constraints. Initial IoT project and block diagrams outline the system architecture, including sensors, actuators, communication modules and power management.
CAD Tools: The use of Computer-Aided Design (CAD) software such as AutoCAD, SolidWorks or Tinkercad allows for the creation of detailed 3D models of the hardware components. These models help visualize the physical layout and design of the device.
Behavioral Simulation: Simulation of the hardware behavior under various conditions using tools like MATLAB, Simulink or specialized IoT simulation software helps identify potential performance, power consumption and signal integrity issues before physical prototyping.
Development Boards: Development boards such as Arduino, Raspberry Pi or ESP8266 provide a flexible and cost-effective platform for testing the core functionalities of the IoT device.
3D Printing: The creation of custom enclosures and mechanical parts using 3D printing technology allows for rapid iteration and refinement of the physical design, ensuring the enclosure is both functional and aesthetically pleasing.
Integration: The prototype is assembled by integrating development boards, sensors, actuators and power supply into the 3D printed enclosure. Ensuring all connections are secure and components are properly aligned is crucial.
Functional Testing: Verification that the prototype performs all intended functions correctly, including testing the sensors, actuators, communication modules and power management system, is essential.
Performance Testing: Performance tests ensure the prototype meets the required specifications, measuring key parameters such as response time, accuracy, power consumption and data throughput.
Stress Testing: The prototype is subjected to extreme conditions such as high and low temperatures, humidity and physical shocks to ensure it can withstand real-world usage scenarios.
Environmental Testing: Testing the prototype in various environmental conditions ensures reliable operation, including resistance to dust, water and electromagnetic interference.
User Testing: User testing gathers feedback on the prototype’s usability and functionality, ensuring the device is intuitive and user-friendly.
Data Analysis: Analysis of data collected from testing identifies weaknesses or areas for improvement, reviewing test logs, performance metrics and user feedback.
Design Refinement: Necessary adjustments to the hardware design are made based on test results, such as tweaking component placement, improving thermal management or optimizing power consumption.
Software Updates: Firmware and software are updated to fix bugs or add new features, ensuring the software is well-documented and maintainable.
Re-Testing: The prototype is re-tested after making improvements to ensure all issues have been resolved and the device meets all requirements. The testing and refinement process is repeated as needed.
Documentation: Detailed documentation of all design changes, test procedures and results is maintained, which will be invaluable for future development stages and troubleshooting any issues that arise.
The development of IoT is an ongoing journey towards better understanding and leveraging the potential of smart devices. Each new project, each improvement, and each innovation is a step forward in this field. Although, it requires to possess not only advanced technical knowledge but also a creative approach to problem-solving and project optimization, IoT hardware development is a dynamic and multifaceted branch. From the design and simulation phase, through prototyping, to rigorous testing and iterative refinement—each step in the process of creating IoT hardware plays a crucial role in ensuring that the final product is efficient, reliable, and market-ready.
InTechHouse offers comprehensive technological solutions that go far beyond IoT hardware. With many years of experience and a development team of experts in fields such as software, industrial automation, artificial intelligence and data analysis, InTechHouse provides an innovative approach to every project. Everything you need – an advanced management system, dedicated software or support in digital transformation, InTechHouse delivers personalized solutions tailored to the specific needs of your business. By choosing InTechHouse, you gain a partner who passionately strives for optimization and process modernization, supporting the growth and success of your company at every stage.
Edge computing processes data locally on the device or nearby, reducing latency and bandwidth usage. This results in faster response times, improved data security and greater reliability for IoT applications.
Modular design allows for easier upgrades, maintenance and scalability. It enables replacing or upgrading individual components without redesigning the entire system, saving time and costs in the long run.
Firmware acts as the software that directly interacts with the hardware components. It is responsible for managing low-level operations, enabling communication between hardware and software and ensuring the device operates correctly.
Factors to consider include range, data rate, power consumption, network topology and interoperability. Popular protocols like Wi-Fi, Bluetooth Low Energy (BLE), Zigbee and LoRaWAN each have unique advantages depending on the application.
Implementing encryption, secure boot mechanisms and hardware-based security modules such as Trusted Platform Modules (TPM) can protect data integrity and confidentiality. Regular firmware updates also help in mitigating security vulnerabilities.
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