Bluetooth LE engineering proven in production
From replacing control and safety cables in warehouse automation to increasing wireless throughput by approximately 9× in rail infrastructure, our work addresses clearly defined technical requirements in demanding real-world systems.
Explore how KNAPP and Hitachi Rail use DEWINE Labs’ Bluetooth LE engineering and software on Nordic Semiconductor-based hardware.
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How KNAPP replaced control and safety cables with reliable wireless communication
KNAPP develops modular warehouse systems in which distributed units must exchange control data and functional-safety signals in real time.
The existing cable-based architecture was proven, but physical connections limited flexibility, introduced mechanical wear and made scaling increasingly complex.
KNAPP needed a wireless communication architecture that could replace two separate physical connections:
Control and status communication
Functional-safety communication, including emergency-stop signals
The system had to provide real-time responsiveness, predictable latency, reliable operation under interference and scalability across dense parallel deployments.
Together with KNAPP, we implemented a deterministic, dual-channel Bluetooth LE architecture on Nordic Semiconductor-based hardware.
The architecture separates standard control and status traffic from time-critical communication. Adaptive radio mechanisms support stable operation in demanding warehouse environments with other wireless systems present.
Wireless replacement of control and safety cables
Zero recorded wireless downtime
All defined timing and safety thresholds met
Wireless communication matching wired-system performance
Greater flexibility and scalability across warehouse systems
Reduced mechanical failure points
How Hitachi Rail increased BLE throughput by approximately 9× without changing the hardware
Hitachi Rail wanted to provide faster wireless access to diagnostic and system data for technicians working with a new generation of ETCS Level 1 equipment.
The existing off-the-shelf BLE module achieved only around 77 kbps. This was too slow for the intended maintenance workflow, but changing the hardware would have increased development effort and technical risk.
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The existing system needed to:
Achieve an agreed throughput target of at least 600 kbps
Provide faster wireless access for technicians
Retain the selected BLE module and hardware platform
Reduce redesign risk within the ongoing product development
We replaced the module’s default BLE firmware with LinkBlu and optimized the complete data path for higher performance.
The firmware-level approach improved communication scheduling, data handling and the interaction between the host system, module and Bluetooth LE stack—without requiring a hardware redesign.
More than 700 kbps BLE throughput
Approximately nine times faster wireless data transfer
Faster access to diagnostic and system data
A usable wireless diagnostics workflow
Existing hardware retained
No hardware redesign required
Different BLE challenges. The same engineering discipline.
The same engineers can stay involved from the initial investigation through implementation and ongoing support.
What should Bluetooth LE make possible in your product?
Your challenge may be different from the systems shown here. The starting point remains the same: understand the product requirements, identify the relevant technical constraints and define a practical engineering path forward. Talk to us if you are:
Product & application
Nordic chip or module
Communication needs
Development stage