Automotive

Case Study: Automotive Black Box for Insurance Telematics

Sector: Automotive

Nature of Project:

BFO Systems developed the firmware for a telematics black box used by a car insurance company. The device was designed to track vehicle location, monitor driver behaviour, detect collisions, and arbitrate fault in accidents. It combined data from multiple sensors to improve accident detection and analysis, ultimately helping insurers respond more effectively to incidents and claims.

Tech Stack Used:

· Microcontroller: STM32 Cortex-M3

· Sensors: GPS, accelerometer, Hall effect sensor, compass

· Communication: 4G modem running Python scripts

· Data Processing: Fast Fourier Transform (FFT) analysis for impact detection

· Message Queue: Streaming accelerometer data to a web service for real-time analysis

· Power Management: Low-power design with internal backup battery

Major Challenge Overcome:

Faulty 4G Modem Modules and Remote Recovery Mechanism

During development, a critical issue arose with faulty 4G modem modules that could become corrupted under certain conditions, making remote recovery impossible. This posed a significant risk, as loss of connectivity would render the device ineffective.

To mitigate this, BFO Systems implemented an innovative self-recovery mechanism. A backup copy of the modem firmware and scripts was stored on the main microcontroller (STM32). If the device detected a modem fault, it could autonomously reflash the modem’s firmware, restoring functionality without requiring manual intervention. This ensured the black boxes remained operational even in adverse conditions, improving reliability and reducing maintenance costs.

Outcome:

The black box device became a major success for the insurance company, positioning them as a market leader in telematics-driven insurance. It provided insurers with enhanced accident data, improved emergency response capabilities, and a more accurate way to determine liability in collisions.