Client: A Global Leader in Automation
Industry: Industrial and Consumer IoT
Systems Services Provided:

• Broadband Analogue and Digital Signal Characterization
• Matlab/Python Signal Processing Research
• Software Defined Radio Reference Implementation
• Fast Prototyping Analogue Hardware and Firmware
• Series Firmware & Hardware Development
• Hardware/Software Integration
• Technical Program Management (TPM)

Preface

Modern products frequently encounter the challenge of integrating with outdated legacy systems. This includes connecting modern IoT gateways to outdated sensors, upgrading industrial automation reliant on outdated communication, and even modernizing military equipment with older RF systems.

This case study demonstrates how we solved a critical integration challenge: deciphering decades-old, undocumented high bandwidth analogue RF protocols. We leveraged broadband analogue and digital signal characterization to reverse engineer these complex protocols, using Software Defined Radio (SDR) for real-time system validation.

Our work highlights rapid hardware and firmware prototyping for quick validation iterations, followed by a thorough development and integration strategy. It also showcases how strategic Technical Program Management (TPM) helped us effectively derisk the path from inception, through to production.

The Challenge: Deciphering of Obsolete & Proprietary High-Bandwidth Analogue RF Protocols

A Global Leader in Automation aimed to integrate a critical new feature into its core product portfolio. The core challenge was to achieve inter-operability with a diverse set of undocumented, legacy analogue communication systems. These proprietary systems were built upon outdated and unsupported broadband signaling schemes, none of which had surviving documentation or accessible reference hardware. The effort required reverse engineering over 50 distinct high bandwidth analogue RF protocols, each with unique modulation characteristics and that too without any prior insight, posing a major risk to embedded development timelines and budgets. To add to this, the final set of protocols was not finalized so we needed to be prepared on all levels for handling surprises later on in development stages.

The Solution: Systematic Reverse Engineering & Parallelized Embedded Development

Research & Analogue Signal Reverse Engineering

Without formal specifications the team began a structured, extremely research-intensive engagement to decode these legacy broadband protocols. Using ‘First Principles Thinking’ over a 4-week focused research phase, the team captured and analyzed raw RF waveform data via high-bandwidth oscilloscopes. Advanced signal processing techniques in Python and MATLAB enabled the identification of the modulation schemes, framing structures, and timing behaviors embedded in the analogue signals. Our inventive and rigorous Analogue Signal Reverse Engineering laid the groundwork for building a reliable protocol interpretation layer atop undocumented analogue hardware interfaces.

Parallel Hardware & Software Development

To achieve a working prototype in just 4 months, our commitment to ‘Bias for Action’ and ‘Project Delivery’ was tested. We initiated three concurrent development tracks:

1. Programmatic Reference Implementation: Developed signal decoding logic using MATLAB and Python to enable functional modeling and repeatable verification of protocol behavior. The implementation was designed with extensibility in mind, allowing rapid adaptation and testing of newly discovered or unexpected protocols during future development phases.
2. Real-Time Software Defined Radio (SDR)-Based Implementation: Built a responsive reference design leveraging Software Defined Radios (SDRs) to emulate and interact with the legacy signal environment in real-time.
3. Specialized Analogue Hardware Exploration: Researched and validated analogue signal processing hardware capable of handling >5 MHz analogue bandwidth and various modulation frequencies—necessary to preserve signal fidelity in high-speed legacy RF systems.

Seamless Hardware/Software Integration & Testing

After crafting both the embedded software decoding stack and tailored analogue front-end hardware, the solution was fully integrated into the client’s embedded platform. Rigorous system-level testing, including in-field validation.

Key Outcomes & Impact for the Client

1. Full Legacy Compatibility: Enabled seamless integration with 50+ undocumented, proprietary analogue signaling schemes.
2. Timely Delivery: Delivered a fully functional alpha Embedded Hardware + Software prototype within 4 months of kickoff.
3. Engineering Risk Mitigation: Significantly reduced the likelihood of costly redesigns through accurate, front-loaded systematic research.
4. Rapid Response to Late-Stage Discoveries: By decoupling signal exploration and validation from physical hardware development, the team leveraged rapid prototyping techniques (fast iteration) allowing discovery and adaptation within hours, rather than waiting weeks for hardware revisions.

Why Better Devices Was the Right Partner

This project highlights Better Devices’ distinct ability to solve technically opaque embedded challenges where conventional approaches fail.

• System-level Approach: We take a holistic, system-level view when designing and prioritizing. This perspective enables us to unlock improvements not just in percentages—but by orders of magnitude. Our baseline target is always 10x gains, not incremental optimizations.
• Expertise in Analogue and Digital Systems: Our team excels at system-level thinking using a combination of signal science, engineering intuition, and domain-specific tools.
• Structured Innovation Under Immense Pressure: A thoroughly disciplined 4-week research cycle, combined with agile SDR development and hardware exploration, enabled us to deliver breakthrough results under tight constraints.
• Time-to-Market Focus: We deliver on aggressive timelines without sacrificing quality. We relentlessly focus on delivering on our commitments.
• Strategic Technical Program Management (TPM): Our structured approach to orchestrating multiple complex technical workstreams and diverse stakeholders minimizes bottlenecks and optimizes resource allocation, ensuring project alignment and efficient production development.

Outlook

Better Devices specializes in overcoming intricate technological hurdles. We recently showcased this by integrating disparate legacy systems, leveraging signal analysis and Software-Defined Radio (SDR) to enable seamless communication. This effort significantly optimized product development and reduced risk. Our core methodology blends rapid iteration with strategic technical program management.

We empower technical leaders to overcome critical integration challenges and de-risk their most ambitious embedded product visions, ensuring superior performance, leveraged technology and market readiness even when dealing with outdated or proprietary embedded systems. Is your team facing challenges with undocumented legacy embedded systems? Do you need to accelerate your next-generation embedded product development with robust solutions? Connect with Better Devices to discuss how our deep expertise can transform your product vision into reality.