How to Bring Your Product Idea to Life: Designing a Bluetooth Low Energy Device with Sensors

What is Bluetooth Low Energy?

Bluetooth is a wireless communication technology that enables data exchange between devices using ultra-short radio waves. It was originally conceived to replace wires in peripheral devices such as computer mice, keyboards or personal computers, but today this technology is already finding its way into smart electronics and other everyday items such as smartphones, laptops, tablets, printers, portable speakers, cameras, robotic vacuum cleaners, joysticks, headphones, watches, medical devices and even athletic shoes.

The wireless communication standard is characterized by minimal energy consumption, compact size and a wide range of tasks to be performed.

The standard’s official technology was first released in 1994 by telecommunications equipment manufacturer Ericsson, which began developing an alternative to wires. In 1998, the SIG group of companies was created to standardize the new protocol. The technology was named after King Harold of Denmark, nicknamed “Blue Tooth”, who in the 10th century reconciled feuding noble families from Denmark and Norway, and the logo is an amalgamation of the initials of the king’s name.

Bluetooth Low Energy (BLE) is a wireless communication technology designed to provide low-power connectivity between devices. It is ideal for applications and devices that require minimal power consumption, such as wearable fitness trackers, smart home devices, and health monitors. Despite the name, BLE is not simply a lower power version of classic Bluetooth; instead, it is a separate technology optimized for short bursts of data transmission rather than continuous streaming. BLE is part of the Bluetooth 4.0 and later specifications, and it coexists with classic Bluetooth, allowing devices to support both technologies simultaneously. This makes BLE a versatile choice for a wide array of modern wireless devices.

There are currently two types of Bluetooth enabled devices: 

• Bluetooth Classic (BR/EDR), basic speed or enhanced data rate. Often used in streaming applications with continuous data transfer and active broadcasting of audio and video content, it is also implemented in wireless speakers, car infotainment systems, headphones and hearing aids.
• Bluetooth Low Energy (BLE), is the one most often used for short-distance data transfer in power-sensitive devices. This spends most of its time in sleep mode, and wakes up when data needs to be sent. For example, in Internet of Things devices, medical, industrial, smart home systems and sensors for its security, event and exhibition devices, and in cases of tracking geolocation of objects.

It is important to note that these types of devices cannot communicate with each other and transfer data, for this reason some smart devices use two types of connection (Dual mode Bluetooth devices), which allows the exchange of information with different types of devices.

Important facts and protocol specifications:

• Both types of Bluetooth operate at frequencies close to Wi-Fi frequencies and equal to 2.4 GHz in the ISM band.
• The entire frequency range is divided into 40 channels of 2MHz each.
• The maximum data transfer rate is 2Mbps.
• Standard data transmission range is from 1cm to 150 meters.
• Power consumption is not more than 15 mA.
• The AES-CCM algorithm is used for data handling with a key length of 128 bits.
• The official specification contains (Classic and BLE), which can be quite confusing when working with documents.
• Availability of unique codes for each device and data encryption capabilities.
• The BLE system appeared in the Bluetooth 4.0 version in 2010.
• In 2016, an improved version was developed with new features that are mainly focused on a low-power standard called Bluetooth 5.
• The protocol’s data transfer capabilities depend on the version on the devices and correspond to the earliest version in case they are different.

Working principle:

In the process of data or file exchange, the frequency hopping spread spectrum (FHSS) method is applied, the feature of which is the frequent change of carrier frequency, which greatly improves the interference immunity of the communication channel.

 The transmission range is divided into 79 frequencies. Each time the frequency changes according to a pseudo-random sequence of numbers known to both the sender and the receiver. So, the main device selects one frequency 1600 times per second and transmits the data packet to the peripheral, after which it jumps around. The devices know how the frequencies will change, so they establish a connection between themselves when other gadgets perceive the signal as electromagnetic noise and cannot track its change. 

This principle can be used to control a smartphone with headphones or a watch, and thanks to the standby function, the devices memorize each other and automatically connect to each other. Once connected, the device can be in one of the following modes: active mode, sleep mode, sleep hold mode or wake-up standby mode.

Protocol components:

The protocol itself consists of several layers. The lowest physical layer (PHY) is responsible for the radio channel of the device. Link Layer (LL) contains the entire byte sequence in the transmitted message. Host Controller Interface (HCI) is the communication protocol between the layers or BLE chips if Controller and Host are implemented on different chips. Logical Link Control and Adaptation Protocol (L2CAP) is responsible for data packet generation and assembly, frame division and error control. Security Manager Protocol (SMP) performs encryption of received data packets. General Access Profile (GAP) is responsible for the initial data exchange between devices to determine “Who is who”. It also includes scanning and advertising processes. 

The range of universal capabilities and competitive advantages contribute to the wide spread and growing popularity of Bluetooth Low Energy devices in various spheres of our life.

The Role of Sensor Technology

With the rapid development of digitalization, touch technology has become an important part of the modern world, gradually penetrating into various areas of life and enabling more efficient and safer interaction with the environment. The convenience and high level of comfort without the use of keys, wires or computer mouse have made touch devices an integral part of our lives.

One important distinguishing quality is the innovative nature of these developments. Touch screen technologies allow us to control devices with the touch of our fingers, which makes the process of interacting with gadgets more natural, simple and intuitive. 

The development of touchscreen technology is contributing to the significant growth in the market for mobile and smart devices such as smartphones, tablets, headphones, and even portable speakers. With touch screens, one can easily and conveniently control their devices, making them more accessible and appealing to a wide audience. 

Technological touchscreen gadgets are becoming an integral part of our daily lives, making it easier for us to perform various tasks and improve the quality of our time. They are used in smart homes to create a more comfortable and energy efficient environment. In mobile devices, sensors detect device orientation and motion to improve the user experience. In medical devices, sensors play a key role in health monitoring.

In industry, there is an opportunity to provide automation and efficiency in the development, manufacturing, testing and production of various products. In manufacturing processes, sensors are used for quality control and equipment condition monitoring. In the transportation sector, sensors are used to operate vehicle safety systems and intelligent transportation systems. 

New technologies that are sensitive to external influences have also found their application in virtual reality. They allow you to interact with the virtual world using your own hands, eyes and other body parts. This makes the use of virtual reality more realistic and immersive.

The widespread popularity and constant use of smart devices in the home opens up new horizons and possibilities of the digital age for users. It is necessary to realize that all the developed devices should not only meet certain quality standards, but also meet the needs of users: to work for a long time without failures, to have an attractive comfortable design, as well as opportunities for interaction with other devices and data exchange.

Real-World Examples

We have already talked about the functions and applications of Bluetooth low power devices. Many of you are probably already familiar with such devices and actively use them in your homes, so here we have looked at specific examples.

Internet of Things (IoT) devices

To this category we can refer to almost all smart and household appliances in our home. These include devices for streaming sound over short distances: headphones, portable and smart speakers, as well as, for example, fitness bracelets that can measure running speed, distance traveled and even heart rate. Smart scales that measure not only body weight, but also the percentage of muscle and fat tissue are also of this type.

Medical devices

Bluetooth LE enables secure data transfer between a wearable sensor and a mobile device or cloud platform, for example, while recording an electrocardiogram or continuously monitoring glucose levels in the body.

Industrial equipment

Sensors and beacons transmit data wirelessly to a central system, enabling efficient and cost-effective monitoring of various parameters, as is the case, for example, in CNC machine tools.

Measurement and safety monitoring devices

The connection parameter contains and controls various intelligent devices. In this way it is possible to regulate the lighting level, temperature, air humidity, door lock closing pressure and the functioning of the security system.

Beacons and receivers

They help provide accurate positioning and navigation indoors. Bluetooth sig is used in retail stores, mobile robotics, museums, hospitals, airports and warehouses. 

Bluetooth enabled devices are used in various appliances and gadgets, which greatly enhances the process of using them. The functionality of the protocol allows it to be implemented in various products using just one chip.

Steps to Design Your Bluetooth Low Energy Product

BLE devices are gradually entering our lives due to their improved characteristics and application possibilities, such as: convenient wireless connectivity, increased security, high energy efficiency and compatibility with most other devices.

The process of development of modern gadgets and high-tech devices is accessible, but not quite clear for both novice manufacturers and experienced developers.

Thus, we can distinguish the following stages of device development: development of the basic concept and idea, design and prototyping, product testing and certification, as well as the subsequent release of goods on the market. The development of a new device is a multifaceted and multifunctional process, in which it is important to provide for even the smallest details in order to further development to meet the needs of consumers.

Idea Generation and Concept Development

Initially, you need to determine what kind of product you want to develop and for what purposes it is needed. You will need to brainstorm, search for relevant information, discuss each idea, identify advantages and disadvantages, and then choose the right one for you.

Define your vision: Think about what the most pressing problem is and how your product can solve it

In this matter, first of all, it is worth to start from the problems that concern you personally, so it will be easier to find their solution. Use your personal design experience and identify ways to solve the problem and choose the best one. Research the feasibility of the idea to see if it is feasible. Draw up a specification of the services to be provided. Explore all the resources you need to make your idea a reality.

Research the market: Know your target audience and competitors 

Think about who will need your product? Define for yourself a specific image of this person, assume their gender, age, social status, marital status, income level, geography of residence, hobbies, pastimes and interests. This information will provide the best way to approach a future customer through your product and solve their problems. Thoroughly research information about existing developments and those that are similar to your idea, or are just starting to appear on the market. Analyze information and recent articles, suggest what you can apply, modernize or eliminate from your products.

Expert advice: AJProTech can help you refine your concept with industry knowledge 

Our specialists have many years of experience in developing technological products, so they are ready to consult and assist in the process of refining your idea and defining its basic concept.

At this stage, it is important not to reject even the craziest ideas at first glance, because it is from such thoughts that devices and systems that later become popular all over the world emerge.

Design and Engineering

This stage involves the industrial design of the device and the design of electronic components: creating chips, selecting the necessary elements, developing software, coding, and creating a working model of the product.

Basics of chip design: Creating an electronic blueprint of your device

In order to make your device work you need to design the product’s electrical schematic diagram, which will be used to create the printed circuit board later on. Identify the main electrical elements, calculate power consumption, currents and voltages. Make sure that there is no current leakage and all components are sufficiently reliable. Use a microcontroller that maintains a sleep mode with low power consumption to increase the run time of the device. A shunt capacitor and several decoupling capacitors and ferrite beads can be used to prevent oscillations. Apply increased trace spacing or add an EMI shield to eliminate possible electromagnetic interference between components. Follow the provided layout recommendations from the BLE manufacturer or use a ground plane. Consider each component’s dimensions, mechanical limitations, and location when laying out the PCB layout.

Selection of suitable components: Selection of suitable sensors and BLE modules 

Based on the technical requirements, select the necessary sensors and modules for data transmission. Consider using a certified and completely off-the-shelf module. This may require a large financial investment, but will greatly speed up and simplify the development process. If you develop the chips yourself, you need to consider different antenna sizes with different transmission power of the Bluetooth module, their placement, susceptibility to electromagnetic interference, and its protocols. Choose the option that suits your idea and realize a certain balance between cost, size and functionality.

Prototyping 

Creation of a working model to test your ideas. At this stage, a quick “rough” implementation of the basic functionality of the product is created to analyze the operation of the system as a whole. Prototyping allows you to look at the developed device, analyze the tasks performed, the advantages and disadvantages of its operation, and make changes if necessary. Prototyping cannot solve all the problems of development according to the technical specification, but it can clearly demonstrate the principle of operation and prepare the development for further testing.

AJProTech offers rapid prototyping services to speed up the product development process. Our engineers will help to develop a device model and optimize power, space and energy requirements according to your request.

Compliance Testing and Certification

Once a prototype of the finished device has been developed, it is important to test and certify for compliance with certain standards, depending on the geography of the product to be manufactured.

Why is this important?

Conducting testing ensures that your product meets all regulatory standards and safety and performance requirements. This is important and necessary to improve the product while it is still in the development phase, to ensure that it meets all quality and legal requirements and does not pose a risk to the user or the environment.

Certification processes

For certification, you should familiarize yourself with the requirements of the region in which you plan to release your product, such as FCC (USA) and CE (Europe). Product certification not only reduces the likelihood of legal issues or monetary penalties, but also increases customer confidence in the product.

AJProTech can help you get tested for compliance with all electronic device regulatory requirements, avoiding typical pitfalls, and our experts will guide you through navigating the major regulatory requirements.

Bringing Your Product to Market

The device is developed, designed, prototyped and product tested, followed by the release of the product into mass consumption through promotional data. Immediately after the release of the product, the target audience will start testing it and giving feedback.

Scaling Production

When the product is released to the market, is in demand and brings a stable positive result, you can move on to development and scaling. 

Quality Assurance

Going forward, the product will need continuous monitoring, quality assurance, support and maintenance for smooth operation and troubleshooting of emerging issues.

Partnering with experts: AJProTech offers comprehensive support for implementing your Bluetooth LE at all stages of product development, allowing you to integrate the innovative system into your electronic device and bring it to the masses. This way, every idea can become a reality in just a few steps.