Embedded System Optimization

About the Customer

A leading industrial equipment manufacturer based in the United States, known for its precision heating systems used across manufacturing and R&D environments. Their products rely on embedded systems for temperature control and communication between sensors, control units, and user interfaces.

The Challenge

Over time, the customer’s embedded control platform had grown in complexity. Multiple products shared similar core logic but with fragmented architectures.

  • Communication between the sensor and control system was slow, causing lag in response times.
  • This impacted temperature precision, a critical factor for both product performance and safety.
  • The legacy architecture made enhancements difficult and slowed innovation.

The customer needed a partner who could understand both hardware and software, and bring structure back to the embedded ecosystem.

Our Approach

BWC Labs worked with the customer’s engineering team to rethink the embedded architecture from the ground up — balancing stability with modern design flexibility.

  • Architecture Redesign : Unified architecture across multiple products, simplifying development and maintenance.
  • Hardware Rework : Redesigned key hardware modules to enhance sensor integration and response efficiency.
  • Logic Development : Rewrote embedded logic to optimize sensor communication and control flow.
  • Code Standardization: Streamlined the codebase for easier versioning, reusability, and future scalability.

The customer needed a partner who could understand both hardware and software, and bring structure back to the embedded ecosystem.

The Breakthrough

Through focused optimization, BWC engineers improved communication speed between the device and sensors by 28x.

  • Faster response enabled the control loop to react in real time.
  • Temperature accuracy and stability improved dramatically
  • The system became more energy-efficient, reducing operational overheads.

The Outcome

  • 28x faster communication speed between sensor and controller.
  • Improved temperature control accuracy and system reliability.
  • Simplified architecture for multi-product scalability.
  • foundation ready for the next generation of embedded innovation.

“Improving the heartbeat of the system — that’s what this project achieved. The new embedded architecture not only runs faster but empowers engineers to innovate confidently”

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