Neurealm designed the solution architecture and developed a functional prototype for a wireless liquid detection sensor node. This project, delivered for a multinational leader in the steel, energy, and textile sectors, involved creating an end-to-end system that detects liquid presence and transmits data to a mobile application via Bluetooth Low Energy (BLE). The final solution provides a path from prototype to production, emphasizing an extremely compact form factor and advanced power management.

Business Context

The client required a specialized industrial sensor solution to monitor liquid levels with high reliability and minimal maintenance. Key business objectives included:
Minimal Footprint: A strict requirement for the smallest possible form factor, achieving a size of just $30\times30$ mm².Operational Efficiency: The need for an optimal battery life and a highly cost-optimized architecture to support large-scale deployment.
Maintenance Ease: A requirement for a sensor probe design that enables easy removal and replacement.
Data Integrity: Ensuring that sensor event logs are preserved even when the primary monitoring mobile device is out of range.

Solutions

Neurealm leveraged its expertise in NRF-based devices and BLE technology to realize a robust, ultra-low-power solution:
Ultra-Low Power Architecture: Selected a specialized ultra-low power SoC and designed firmware utilizing deep sleep modes to maximize battery longevity.
Smart Data Management: Optimized flash write cycles and RAM retention to store local sensor logs, preventing data loss during connectivity gaps.
Power Awareness: Integrated battery voltage sensing to proactively alert users via the mobile app when power is low.
Optimized Connectivity: Configured BLE advertisements at 2-second intervals to balance responsiveness with power conservation.
User Interface: Developed a user-friendly mobile application to receive real-time alerts and manage the sensor node.