Real Case: Lessons from Wind Turbines

Approximately a decade ago, a batch of BLIIoT devices was installed on wind turbines. Initially, they operated normally, but as soon as the turbines connected to the grid for power generation, the devices would crash. Once the turbines disconnected, the devices returned to normal. Despite on-site inspections by engineers, the root cause remained elusive. Finally, during laboratory testing, we discovered that grid connection produced intense electrical pulse interference, which coupled through the Ethernet port and power supply, affecting the device's chip and causing crashes.

This experience led us to significantly enhance hardware protection and anti-interference capabilities in our designs.
 

Common Issues Without Adequate Protection

• Unstable Communication, Data Loss, or Delays

Industrial environments with frequent electromagnetic interference can cause packet loss, data errors, or delays, severely impacting system real-time performance and reliability.

Typical Scenarios:

1) Intermittent sensor data upload interruptions hinder real-time monitoring.

2) Delayed or lost control commands result in production line halts or defective products.

• Interface Failures and Hardware Damage

High-frequency interference, surges, and electrostatic discharge may damage communication interfaces (e.g., RS485, CAN, Ethernet) or even burn out ports or entire devices.

Typical Scenarios:

1) Interfaces fail after thunderstorms, causing system downtime.

2) Static discharge during cable insertion damages chips, making ports unusable.

• Frequent System Crashes or Restarts

Devices lacking anti-interference capabilities often crash or restart under strong electromagnetic conditions, reducing operational efficiency.

Typical Scenarios:

1) Devices near welding equipment or inverters restart unexpectedly, causing data loss.

2) Systems crash after prolonged operation in high-interference environments.

• Abnormal Analog Data Collection

Interference signals in industrial environments can distort analog input, leading to erratic or completely inaccurate data collection.

Typical Scenarios:

1) Temperature, pressure, or current signals fluctuate abnormally, rendering them useless for control decisions.

2) Data charts are filled with spikes, drastically reducing analytical value.
 

Conclusion

Industrial environments impose stringent demands on the protection and anti-interference capabilities of equipment. Only through scientific design and rigorous testing (e.g., ESD, electrical fast transients, surge immunity) can long-term stability be ensured in complex scenarios. This principle underpins the core design philosophy of our ARMxy series products.