Embedded Systems
Embedded software is where predictable behaviour lives. It’s the quiet layer that turns hardware into a dependable system – reading sensors, driving actuators, enforcing safety states, logging evidence and sending only the signals that matter. At TAD, we design and deliver embedded software for control systems, ultra-low-power telemetry and operator HMIs that must work first time, every time.
Summary
Why embedded software matters
In the field, failure modes aren’t theoretical: vibration induces false edges, power dips corrupt state, noisy inputs chatter alarms, and “chatty” comms flatten batteries. Well-engineered firmware prevents cascades. Deterministic control loops keep machinery inside safe windows. Debounce, hysteresis and plausibility checks turn raw signals into trustworthy decisions. Brown-out and watchdog strategies bring devices back cleanly after abuse. The result is boring reliability – exactly what you want around heavy kit, cold-chain cargo or public infrastructure.
Our approach
Define decisions, not dashboards
We begin by asking what actions the device must support (locally and upstream). That gives us acceptance criteria for latency, accuracy, and power budget, plus a clear data model: which events are critical, which are trends, and what must be retained if the link drops.
Architecture that fits reality
Bare-metal where timing is tight; an RTOS when tasks (I/O, control, comms, UI) need clean scheduling. Memory maps are sized with headroom; persistent data is protected against corruption. Power domains and sleep states are planned early; wake-on-event is the default for battery-backed systems.
Control, sensing and safety
Real-time control with interlocks and safe states; sensor validation with range checks and cross-checks; fault trees for edge cases (stalled actuator, sensor disagreement, brown-out). When something goes wrong, behaviour is explicit and recoverable.
Interfaces that reduce error
From rugged, symbol-led HMIs to minimal service UIs, we prioritise clarity under pressure: obvious states, guarded risky actions and consistent workflows that work across multilingual teams.
Connectivity that’s calm and secure
Cellular/Wi-Fi links are engineered to be boringly reliable: rate-limited reporting, back-off and store-and-forward when coverage is patchy. Devices enrol with authenticated credentials; firmware images are signed and rollback-safe; OTA updates can be staged and resumed.
Test like the real world
Bench harnesses, thermal/vibration cycling, EMC noise injection and “messy” scenarios (doors left ajar, repeated power dips, intermittent coverage). Structured field trials validate actual current draw and confirm that alerts remain calm outside the lab.
Have a query or need to reach out?
Click here to get in touchWhat we build
- Deterministic control firmware for hydraulics, drives, refrigeration and safety interlocks.
- Ultra-low-power telemetry stacks with event-driven reporting and long battery life.
- HMIs and service UIs that surface the next safe action, not just another chart.
- Secure bootloaders and OTA with signed images, rollback and audit trails.
- Diagnostics and logs that cut time-to-fix: structured events, error maps and on-device tests.
- Manufacturing support: production test firmware, calibration routines and golden images.
Real-world examples
Hi-Force – Synchronised lifting systems
We implemented deterministic multi-channel control with guarded states and touch HMIs that present only the essentials. Firmware keeps lift points within tolerance, pauses safely on anomalies and provides clear diagnostics – ideal for moving imbalanced loads where a mistake is costly or dangerous.
Hultsteins – Multi-zone refrigeration control
Embedded code orchestrates zones, defrost cycles and alarms, with a symbol-led HMI for international fleets. Browser-based setup over an onboard access point and CAN Bus integration give depots clearer diagnostics and reduce service time – without swamping teams in alerts.
BT – TAD-220 – Covert theft detection
A low-power GSM device that sleeps deep, wakes on a precise event and sends concise, validated messages. Firmware focuses on power discipline, reliable signalling and graceful recovery – proof that simplicity, done well, is often what endures.
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Quality built in
- Determinism first – Time-critical paths are measured and budgeted; non-critical work is deferred.
- Fault-tolerant by design – Watchdogs, brown-out handling, safe defaults and transactional updates.
- Low-power discipline – Wake-on-event, adaptive sampling and measured current profiles.
- EMC-aware I/O – Filtering and debounce that cope with real electrical noise.
- Secure lifecycle – Authenticated provisioning, signed updates, auditable configuration.
- Maintainable code – Modular structure, consistent patterns and documentation that another engineer can pick up.
How we work with you
- Scope the behaviours, constraints and acceptance tests (what must be true for “safe”).
- Prototype fast so you can exercise behaviour on rigs and in situ.
- Iterate with evidence – logs, traces and power profiles – to tune thresholds, timing and sleep states.
- Harden and hand over – architecture notes, error maps, commissioning flows and production test firmware.
- Support the fleet via our Lifetime Support: OTA updates, diagnostics, refurbishment and obsolescence planning.
Case Studies
When to call TAD
- You need safe, predictable control around hydraulics, drives or refrigeration.
- Battery life targets aren’t met, and you need wake/sleep strategies that work.
- Alerts are noisy or misleading, and you want exception-first telemetry.
- You’re rolling out OTA at scale and need signed, rollback-safe updates.
- A redesign is forced by component changes, and the firmware must migrate cleanly.
Ready to ship firmware you can trust?
Whether you’re launching a new platform or stabilising an existing one, we’ll help you deliver embedded software that behaves predictably and scales with confidence. Get in touch to map a route from requirements to tested, maintainable firmware – without surprises.
