Industrial IoT Pulse Controller for Self-Service Systems

Project Overview

Rashid Tech Solutions partnered with a European client to develop a reliable Industrial IoT Pulse Controller for self-service car wash and vacuum systems. The objective was to build a secure, production-ready embedded solution capable of controlling industrial equipment while maintaining reliable communication with cloud infrastructure.

The project focused on delivering firmware that could operate continuously in demanding environments, ensuring accurate pulse control, secure remote management, and long-term stability.

Client Challenge

The client required an embedded controller that could:

• Execute pulse commands with high accuracy.
• Prevent duplicate command execution.
• Maintain secure communication with cloud services.
• Support remote firmware updates.
• Recover safely after unexpected power interruptions.
• Operate reliably with minimal maintenance in commercial environments.

Since the controller was responsible for managing customer-operated equipment, reliability and fault tolerance were critical requirements.

Our Solution

Our engineering team designed a complete firmware architecture using the ESP32-S3 platform, built specifically for industrial deployment.

The firmware was developed with a modular architecture, separating networking, command processing, pulse generation, configuration management, logging, and system monitoring into dedicated components. This approach improved maintainability while ensuring stable long-term operation.

Secure MQTT communication was implemented for reliable cloud connectivity, allowing the controller to receive commands, transmit status updates, and synchronize with backend systems.

To simplify maintenance, we integrated secure Over-the-Air (OTA) firmware updates with rollback protection, enabling remote software upgrades without requiring physical access to installed devices.

To improve reliability, watchdog monitoring, persistent command storage, duplicate command protection, and automatic recovery mechanisms were incorporated to ensure safe operation even during network interruptions or unexpected power failures.

Key Features

• Industrial-grade embedded firmware
• Secure MQTT communication
• Reliable pulse generation
• OTA firmware updates with rollback support
• Command persistence
• Duplicate command prevention
• Automatic recovery after power interruption
• Remote device monitoring
• Modular firmware architecture
• Designed for long-term industrial operation

Results

The completed solution provided the client with a stable and scalable embedded platform ready for integration into commercial self-service equipment.

The firmware architecture allows future expansion while maintaining the reliability required for unattended industrial systems. The project successfully delivered secure communication, remote firmware management, and dependable pulse control within a production-ready embedded solution.