Customer

European manufacturer of optical systems.

The objective was to develop a hardware and software platform for a system of two controlled high-resolution video cameras and controlled light sources. Video data are further submitted to the user PC where the images are analyzed depending on the parameters of light sources.

A video system was developed: video camera board with a digital SXGA CMOS sensor, light sources and video cameras switch board, image capture, storage and transfer (via the ISA bus to the operator's PC) board. Data transfer from the switch board to the video capture board was implemented through a high-speed protocol LVDS (80 Mbps). Image capture and recording are performed in real time at the speed of 12 frames per second.

For an FPGA chip, a set of IP cores was prepared:

• ISA bus controller;
• DMA channel controller;
• SRAM controller;
• CMOS sensor controller. 

An ISA device driver under Windows 2000 was developed to transfer data to a PC. System setup, image display, control of video cameras and light sources parameters is done via an especially implemented client application.

• High-resolution video capture (1280x1024);
• Simultaneous capture of up to 6 frames within 1/2 second at most;
• Control of 16 programmable light sources;
• ISA interface. 

Design tools	Xilinx ISE foundation, ModelSim
Technologies	VHDL
Hardware and interfaces	ISA, DMA, LVDS, SRAM
Programming languages	Visual C++, MS Windows DDK, Win32 API
Project management tools	dotProject, MSProject, CVS
Efforts	520 man-days
Duration	18 months

Customer

Manufacturer of large and giant information and advertising LED boards

The objective is to develop soft-hardware platform for controlling high-resolution electronic board which is built from big quantity of universal LED cells. It is necessary to provide platform scalability by applying Embedded Linux OS, while the device cost must not exceed 60 USD when manufactured in a medium run.

As the basis for hardware platform we choose an inexpensive RDC R8610 processor that has x86 core architecture, 32-bit RISC core and 133 MHz. This processor has a big set of built-in periphery (PCI rev2.1, 2 x Ethernet MAC, USB 2.0 Host, LPC, UARTs, GPIO, SDRAM-controller), and its performance allows executing processing tasks and displaying various graphics onto information board. The selected microprocessor does not require any cooling system.

ST FLASH M29DW128 (NOR organization type) stores bootstrap loader, operating system, application software and controller's settings. Samsung FLASH K9F5608 (NAND organization type) stores commercials and other multimedia information and has 1Gb memory. NAND Flash controller is realized on Altera CPLD MAX2 EPM270, and also a specialized interface is implemented on this crystal for displaying information on the board.

Besides this the board has RTC DS12CR887 real time clock, PHY Ethernet DP83848 physical layer, SDRAM Samsung K4S281632F-TC(L) and TI TUSB6250PFC chip acting as a bridge for connecting storage devices with ATA/ATAPI interface for connecting to USB 2.0.

The board is made in "Euromechanics" form-factor in accordance with the PCI standard requirements. By external interfaces we provided protection of electric circuit by using galvanic isolation and filter circuits. Despite the circuit density and presence of PCI edge connector on the board, we performed the routing in four layers.

The controller provides the following functions:

• Displays information on the information board via LPC interface;
• Polls temperature, pressure, humidity, radiation sensors via GPIO;
• Connects a usual USB-keyboard for direct board control;
• Performs remote control over the device via Ethernet;
• Connects wire- and wireless modems via RS232;
• Connects ATA/ATAPI storage devices;
• Connects graphics accelerator via PCI bridge.

We developed board support package (BSP) on the basis of RedBoot bootstrap loader and Linux operating system. We modified RedBoot to support OS download from NOR FLASH M29DW128 and work with K4S281632F-TC(L) SDRAM memory. Our specialists considerably redesigned basic Linux distribution kit with the 2.6.8ac1 core from RDC and adapted it to new hardware platform. They added new modules to work with memory (MTD support), to assemble installation package of embedded software, to protect program code from copying.

Controller's embedded software can work with different information board resolutions and it supports several types of LED cells. Operator's interface is realized with application of modern Web-technologies. Web-server works under control of embedded Linux and it provides user interaction with internal controller's functions via graphical Web-interface.

The software performs the following main functions:

• Controls screen via Web-interface and displays information on the information board;
• Configures controller and sets screen parameters;
• Splits access rights into user groups (operator, administrator, engineer);
• Generates schedule of appearance of advertising and information announcements;
• Performs more than 20 effects of displaying information on electronic board (shows creeping line, changes movement speed, displays various appearance effects, sets pauses, configures brightness);
• Provides direct control when USB keyboard is connected to controller;
• Displayed graphical information and supports standard TTF fonts;
• Tests correctness of displayed information via built-in simulator of object display on real board.

• Application of Linux OS and use of ANSI C for programming provide portability of program code to other hardware platforms and absence of licensable solutions to pay royalties for;
• Web-interface allows working with the board via internet browser from any PC (mobile device) without having to install additional software;
• Program code is copy-protected;
• CPLD can be programmed remotely in-circuit;

Technologies	Redboot, JFFS2 , Embedded Linux, AJAX
Programming languages	C, C++, VHDL, ASM x86
Interfaces	Ethernet BASE T10/100, USB HOST 2.0, LPC, RS232, PCI
Development tools	IDE Eclipse, GNU Toolchain (gcc, gdb), Quartus, PCAD
Project management tools	dotProject, MSProject, CVS
Efforts	180 man-days
Duration	6 months

Customer

American-Russian developer of digital home media-systems

To develop a programming platform for a Linux-based home multimedia center. The platform should enable one to play music, view video, record and view TV programs, record multimedia data on CDs or DVDs, as well as other multimedia functions. The center is controlled with a remote control.

The software should be installed from a startup installation disk.

The system is based on a custom Linux distribution with partial basic functionality supporting operations with multimedia data.

Recording of TV programs and the "record during pause" functions are implemented with the Video4Linux interface, embedded into the Linux core and ensuring interfacing with TV tuners. A Samba client-library was used to access network resources of a local network (Windows shared folders) via the CIFS protocol. Support of the remote control was implemented through LIRC libraries.

Custom installation distribution based on a standard graphics Linux installer.

Convenient and flexible user interface; Support of various TV tuners and remote controls; Download support of multimedia data from FTP and Windows Shared Folders; Support of streaming video and karaoke; Background recording of TV programs to HDD during playback; Graphics output to an LCD screen, TV receiver, projection display.

Technologies	Simple DirectMedia Layer (SDL) cross-platform media library, Video4Linux API CIFS, Samba, LIRC
Programming languages	C++
Project management tools	dotProject, MSProject, CVS
Efforts	420 man-days
Duration	7 months

Customer

Developer of set-top boxes (STB), devices that receive a satellite, cable, ground, or Internet digital video signal and subsequently direct them to the TV screen. A fierce competition on the STB marker demands the manufacturer to deliver a product with minimal time-to-market and extremely cheap hardware.

It is characteristic of an STB to have an advanced user interface that allows setting up a satellite antenna, scanning transmitted streams, editing channel lists, viewing EPG, schedule tasks, etc.

The goal was to create a software framework that would allow the customer to change the user interface with minimal efforts in order to quickly create new models on the basis of the existing universal platform. Such approach significantly reduces the development costs of each individual STB model.

An STB that receives satellite TV channels (DVB-S) utilizes the MIPS-based ALI M3329 chipset. The system runs under TDS2.

Due to absence of project software documentation, we had to analyze (using the reverse engineering principle) the source code and UI logic to elaborate an efficient solution and its implementation.

Normally, when it is often required to change the UI appearance, it is not hardcoded. Instead, a module (engine) is created that generates UI at run time according to the configuration file. However, such approach was not possible for the project due to limited CPU performance.

Therefore, it was decided to make all changes at the source code level. For this purpose, all parameters affecting the appearance (control elements coordinates on the screen and their styles) were moved into separate header files as macro definitions.

Cygwin and GCC 3.0.4 (mips-t2-elf) compiler were used as development environment.

The resulting software package completely satisfied primary project objectives. The functionality of the solution is the following:

• Software running under MS Windows that allows easily changing parameters affecting GUI appearance and global settings;
• All parameters are saved into an XML file;
• Parameter values are checked by the XSL validator;
• XSL transformer whose activation is integrated into the project makefile generates several header files (*.h) from the XML file;
• Header files are used to compile and build STB binary modules with modified user interface;
• The entire check, generation, and build process is automated.

The project was implemented within shortest terms and with minimal efforts, as required by the customer. Knowledge of the specialized area that was obtained during the project allowed maintaining mutually beneficial cooperation with the customer.

Technologies	Cygwin, XML
Programming languages	C/C++, XSL
Design tools	GCC
Project management tools	Test Track Pro, SVN, MS Project, MS SharePoint
Efforts	80 man-days
Duration	3 months

Customer

The Aladin company, supplier of components and comprehensive solutions for agricultural machinery.

To develop, conduct experiments and prepare design documentation for mass production of the in-car harvester-thresher monitor, which analyzes technological operating modes and controls harvesting parameters. The challenge lay in creating a competing product in price and under strict time constraints.

The development fit extremely tight timeframes, with the first prototype created in a month and a half after development had started.

A technical level map with comparison features of competitive products was compiled. On its basis, functional and technical characteristics for a new product were determined, plus some unique features were suggested:

• An event log to control the operating modes of the machinery;
• Custom sensor sensitive parameters for various crops;
• CAN interface.

By agreement with customer, specification requirements for hardware, software, and design were elaborated and validated.

We implemented an electric schematic diagram on the basis of the AT90CAN128 microcontroller, with a possibility to use MCU ATmega128 in a low-cost model. An interface with a high-resolution LCD was developed.

Power outputs and power circuit were protected from polarity reversal and short circuit, and integrity control was ensured for connection lines of external sensors. The device has an inherent capability of on-board programming and firmware update that does not require opening the enclosure. Large-scale nonvolatile memory storage allowed saving events with real time reference.

An appealing and easy for the eye front panel represents a film membranous pad displaying intuitive icons. The graphical interface comprises around 30 screens with 240x128 resolution, thus making user interface convenient and adaptive.

The enclosure is based on the OEM solution by OKW. The enclosure design compiles with the All-Union Standard on in-car electronic devices for agricultural machinery in dust- and waterproofness (IP65), shock and vibration resistance. The modular design simplified the assembly and increased repairability of the device.

The side panel of the screen has separate slots for the CAN interface, a technological slot and a programming slot. The device can be mounted in any suitable place of the driver booth with an external bracket.

A sketch map of the graphical user interface has been made that became the basis of writing the GUI programming code. The algorithms of collecting statistical data about the machinery maintenance enable the warranty and post-warranty services quickly detect the source of trouble. A package of firmware and application software combines the graphical interface with technological machine control functions.

At the beginning of design process, specification requirements were checked for compliance with the All-Union Standards, later at the prototype preparation stage the device was tested for compliance with specification requirements.

The user interface was field tested and received feedback from combine operators, which allowed making changes to increase the convenience of use.

• Short terms and low project cost as a result of comprehensive approach to design;
• Convenient graphical user interface;
• High-contrast high-resolution screen in a low-cost device;
• Unique features that were elaborated after analyzing similar products.

Design tools	P-CAD, AutoCAD, CorelDraw, AVR Studio, IAR, AVR GCC
Technologies	CAN, LIN, FSTN LCD
Programming languages	ASM, C
Project management tools	dotProject, MSProject, CVS
Efforts	140 man-days
Duration	2,5 months

Customer

German network equipment and wireless devices manufacturer.

Add SSL (Secure Socket Layer) support for SOAP applications running on the customer's MIPS boards under uCLinux. The OpenSSL library was not recommended as it did not meet size constraints for the embedded application.

Due to size constraints NOR flash memory of the hardware platform, the choice of an SSL library became quite a challenge. A thorough analysis showed that the axTLS library would be the best to replace OpenSSL, though initially the customer's SOAP application used OpenSSL.

To minimize development efforts during transition to axTLS, it was decided to develop a wrapper for OpenSSL API calls. Thus, the source code of the original SOAP application did not require changes, while OpenSSL calls were directed via the wrapper into axTLS calls.

• axTLS allowed reducing the size of the SSL part to 75 KB from the original 800 KB with OpenSSL;
• The axTLS wrapper did not require any modification of the original SOAP application.

Technologies	SSL, SOAP, uCLinux
Programming languages	C
Design tools	GCC
Project management tools	MS Project, CVS
Efforts	20 man-days
Duration	1 months

Customer

Joint German-Belarusian venture "Proscan Special Instruments" develops devices for industries, scientific researches, laboratory diagnostics and medicine.

The task is to develop embedded software for operating internal equipment of HS 301 camera and to implement remote control via Ethernet-interface.

The development of software for control card is necessary to create visualization system and register low luminous fluxes received from spectral equipment.

Cameras are designed to receive high-quality images from solar-cell matrix (2048x2048 pixels) in the wave-length range from 400 to 1000 nm. They can be used as part of optical and electronic microscopes or as registration system in spectral devices of various purposes.

Alongside with optimization of embedded Linux distribution for PC104 Advantech PC-3350 (RAM 64Mb, Flash 64Mb) hardware platform, our team developed software that has the following functions:

• Initialization and testing of equipment when switching HS301 camera;
• Continuous monitoring of equipment status;
• Connection to external computer via Ethernet-interface;
• Reception of commands from external computer via dedicated protocol and their execution;
• Setting CMOS matrix operation modes via SPI interface;
• Data acquisition via ISA bus from FPGA Xilinx Spartan3 based card that collects preliminary information and processes it;
• Control other equipment of HS301 camera;

• Snapshot (limited) mode;
• Non-stop mode;
• Full image with maximal resolution mode;
• Full vertical binning mode;
• Single-track mode;
• Multi-track mode;
• Regions mode;
• 8, 10, 14-bit read with 48 MHz sampling rate mode.

Photo detector type	CMOS Fillfactory LUPA-4000-M photo detector
Solar cell (pixel)	12x12 µm
Photosensitive field size	24.576x24.576 mm
ADC capacity	8, 10, 14 bit
Camera dynamic range	Not less than 67 dB
PC communication interface	Ethernet 100 Base-T

• Adapted Linux distribution to use in series of devices;
• Extended support of configuration files for creating new cameras without any changes in source code;
• Diskless logging system;
• Creation of universal protocols for series of devices;
• Emulator mode for quick debugging of new client software functions.

Technologies	Embedded Linux, PC/104, Ethernet, ISA
Programming languages	ANSI C, C++
Tools and interfaces	GCC, GDB, Eclipse
Project management tools	MS Project, CVS
Efforts	40 man-days
Duration	1,5 months

Customer

JV "Proscan Special Instruments" whose key area is development of devices for industry, scientific investigations, laboratory diagnostics, and medicine.

To develop an embedded Linux distribution for company products as a software platform together with hardware platforms on the basis of Advantech PC/104 industrial computers. The distribution should meet the following main requirements:

• OS should be based on a Flash Card of up to 64 Mb;
• RAM capacity of 64 Mb;
• File system should ensure data security at shutdown;
• File system should ensure a possibility to create, store, change own data during operation of the device;
• OS should support both text and graphics (640X480 16 bit) modes;
• OS should support a possibility to install and uninstall own programs;
• OS should function on the PC/104 and PC/104+ controllers.

A specialized Linux distribution of 6 Mb was developed for an industrial PC/104 computer, with support of Ethernet, Web-Server.

The distribution is tailored to work on Advantech PC/104 industrial computers - PCM 5820 and PCM 3350 models; on PC/104+ - the PCM3370 model. A BSP to support these hardware platforms was created.

Support of the following devices and peripherals was implemented:

• Chipset NS CX5530 core;
• RTL8139 and Intel 82559 ER network Ethernet-adapters;
• 4 COM ports;
• LPT port;
• 4 USB 2.0 High Speed ports;
• LCD, TFT, CRT screens and monitors;
• "mouse" input devices on a PS/2 port;
• keyboard working with at least two languages;
• ISA (PC/104);
• PCI (PC-104+);
• Floppy drive;
• CD-ROM drive;
• HDD drive;
• USB Mass Storage devices;
• DMA-channel of the ISA-bus;
• Possibility to add Ethernet Gigabit support.

• An embedded Linux distribution supporting system utilities on the basis of busybox takes up 6Mb, which resulted in additional 58Mb (on a 64Mb Flash-card) for data storage;
• Linux OS file system is secured against unauthorized copying.

Design tools	GNU Toolchain (gcc, gdb, binutils, glibc)
Technologies	PC/104, PC/104+
Interfaces	USB, PCI, ISA, IDE, DMA, TFT/STN, CompactFlash II, Ethernet 10/100
Programming languages	C, Shell
Project management tools	dotProject, CVS
Efforts	35 man-days
Duration	1 months

Customer

"The Planet of Attractions" Ltd is engaged in designing and manufacturing modern high-technology amusement parks.

The objective is to develop, manufacture and test experimental models of game platform controller. The controller must perform the following functions:

• Calculate spatial coordinates of platform location depending on game situation;
• Calculate motor control actions taking into account the inertia and characteristics of the platform;
• Store the settings and parameters of the platform in non-volatile memory;
• Use one hardware platform as simulator for different attractions and games;
• Interact with PC via digital interfaces;
• Process data from location sensors of actuating mechanisms.

The platform is designed for use as part of different amusement complexes and it works as auto-, air-and other motion simulators.

For the solution of the objective we suggest implementing controller on the basis of Analog Devices BlackFin BF532digital signal processor. The solution is oriented to provide big computational power for executing control algorithms and calculation of spatial coordinates.

We applied NAND Flash Samsung K9K8G08U0M-PCB0 chip in the controller with the view to store big data array for various games and attractions, and built-in USB interface allows uploading all settings into the controller as separate files, as into general USB Mass Storage device. The developed protocol for communications of the device with personal computer provides the functions of in-circuit programming, interaction with game programs and functions of platform telemetry (automatic testing, control, operation modes, analysis of location and sensors' state).

The device can provide simultaneous control over 42 motors. It is possible because of six analog outputs for direct inverter control and six RS-485 digital interfaces built into the card. Each RS-485 (UART) interface, in its turn, can control six inverters. UART digital channels are implemented on CPLD microchip of MAXII EPM570T100 family.

In-circuit device programming can be realized via RS232 or USB2.0 interfaces. The USB Philips ISP1362 controller used in the chip allows operating in USB Host, USB Device and USB OTG modes.

We implemented additional protection elements in connection with stringent requirements in electromagnetic compatibility (EMC), determined by close position of platform strength elements. EFT/ESD filters and optical relay were used in external communication interfaces to eliminate the noise influence from working frequency converters and powerful motors of alternating current. Analog circuits and digital algorithms of filtration were applied to eliminate noise of analog input signals from location sensors of actuating mechanisms.

• The use of high-performance BlackFin BF532 processor allows application of complex algorithms for platform control with big quantity of degrees of freedom;
• The controller can provide independent control over 42 motors of alternating current;
• The controller can be used both as a part of game simulator and in training simulators for drivers of different transport vehicles;
• The device can be used as motor controller for different fields of human activities (for example, in systems of precise positioning of mechanisms).

Development tools	VisualDSP, P-CAD, Quartus, MVS
Technologies	NAND Flash, RS232, RS485, USB2.0, DSP
Programming languages	C, C++, ASM
Project management tools	dotProject, MSProject, CVS
Efforts	65 man-days
Duration	3 months

Customer

LLC "Rovalentspetsservis" supplies objects of any complexity degree with modern security systems. It offers a full spectrum of own-made equipment - from sensors and simple home alarm systems to powerful security complexes for large enterprises.

The task is to develop, produce and test experimental model of access controller intended to control staff's access to the enterprise and operate the turnstile, electromechanical and electromagnetic door locks.

The access controller is designed to:

• Manage turnstile or electric lock status;
• Control passage direction;
• Connect to different types of readers;
• Keep key codes;
• Record event log;
• Exchange information with other controllers from enterprise network;
• Exchange information with computer.

We offered a concept to organize the network with access controllers capable of exchanging information between them. Our team developed protocols and suggested RS485 interface as most appropriate for our solution (high reliability with fewer man-hours during implementation).

The team developed principal electric scheme, circuit board and software for Atmega162 microcontroller. The device uses FRAM-based memory with unlimited number of re-write cycles to store the event log. The following features were realized in the device:

• Power outputs and power circuits are secured from repolarization, short circuit and voltage swing;
• Possibility of in-circuit programming and software upgrading;
• Protocol to transmit event log to computer;
• Built-in software for two devices on the basis of one hardware-based platform with different prime cost.

• Usage of FRAM-based memory;
• Connection of different operating devices (turnstile, electric lock);
• Network with various number of access controls (from small companies to large enterprises);
• Low prime cost of end product.

Technologies	FRAM, RTC, RS485,1-Wire, IButton, Wiegand
Programming languages	C, ASM
Tools and interfaces	AVR Studio, PCAD, AutoCad
Project management tools	MS Project, CVS
Efforts	60 man-days
Duration	2 months

Customer

Research and production complex Kontakt develops and supplies control panels, membrane switches, indicator dials.

The main customers of the company are manufacturers of specialized machinery, trade scales, dispensing apparatuses, welding machines, measurement devices, heat, water, and gas meters, flow meters, taximeters, flaw detectors, machine tools with cnc.

The objective was to develop, conduct experiments, and prepare design documentation for mass production of a control panel that manages the agricultural machinery inventory Polesie-800. The team was challenged to create reliable control panels, conduct experiments and prepare mass production by the start of harvesting campaign.

A schematic diagram was developed on the basis of the AT89C51CC03 microcontroller, a CAN interface was implemented for further scaling of the device and connecting of additional equipment.

Power outputs and power circuit were protected from polarity reversal, short circuit, and overvoltage. There is also a possibility of fine adjustment of keyboard highlighting, on-board programming, and firmware update. A modular design allows using a controller with a wide specter of various panels.

• CAN interface;
• Modular design.

Design tools	IAR, PCAD, AutoCad
Technologies	CAN
Programming languages	C
Project management tools	dotProject, MSProject, CVS
Efforts	37 man-days
Duration	1 month

Customer

The project is made by an internal Promwad request.

The objective was to develop an OEM-module on the basis of the Intel PXA255 microcontroller to further employ in low-consuming mobile devices with integrated high-resolution screens. The following interfaces should be implemented on the module: Ethernet, Full-speed USB OTG, RS-232, TFT LCD with a Touch Screen controller, system extension bus, real-time clock with an independent power supply.

The module design should ensure secure placement in the target system, shock and vibration resistance, electrical connection with the chassis of the target system. The key requirement to development was to minimize the module size (to the size of a cigarette pack).

A number of current solutions were analyzed for advantages and disadvantages. The comparison data helped elaborate requirements to the module and develop a schematic diagram. Low power consumption, industrial temperature range and balanced cost are ensured by the Ethernet controller SMC LAN91C111I-NE, USB Host/OTG Philips ISP1362 controller, StrataFlash Intel PC28F256J3C125, and SDRAM Micron MT48LC16M16A2FG.

The non-standard design had to model the integrity of system bus signals beforehand. The results of such modeling became the basis for a concept of board tracing. A small size and high density of the components required using the High Density Interconnect (HDI) technology, blind&buried microvia in particular. During the stage of components placement we paid special attention to convenience of control and commutation elements, separation of signal paths, and uniform distribution of the released heat. After the tracing had finished, a complete modeling of the printed circuit board layout was done to ensure signal integrity, crosstalk, and electromagnetic compatibility.