Project Overview
I owned the complete technical architecture and delivery of the Digi XBee Intelligent Edge Controller (IEC), a cloud-managed LoRaWAN intelligent edge controller designed to retrofit existing industrial sensors and systems with long-range wireless connectivity and local decision-making.
The IEC combines a Silicon Labs EFR32 MCU running FreeRTOS with the Digi XBee-LR LoRaWAN module (US915 / EU868), enabling sub-second local monitoring, rule-based processing, and alarm generation while significantly reducing network traffic. The platform upgrades legacy Modbus RTU, analog, and digital industrial sensors into modern, cloud-connected systems without requiring on-site compute infrastructure.
The product was originally designed and built at Haxiot, where I led the early system architecture, firmware development, and low-volume production fixtures. Following Digi’s acquisition of Haxiot, I brought the IEC platform into Digi, where it was industrialized, scaled, certified, and fully integrated into the Digi X-ON IoT platform for higher-volume manufacturing and global deployment.
A core design goal was to place intelligence directly at the edge, enabling fast local responses, minimizing unnecessary LoRaWAN uplinks, and maintaining centralized visibility and control through Digi X-ON.
Edge Intelligence & Deployment Model
The IEC executes deterministic, low-latency edge intelligence directly on the device, supporting up to 80 local edge rules with unlimited cloud-based rules for higher-level orchestration and fleet-wide policy management.
This architecture enables:
Sub-second local monitoring and alarm generation
Over 99% reduction in LoRaWAN network traffic through local evaluation and filtering
Reliable operation during intermittent or unavailable backhaul connectivity
No LoRaWAN expertise required for installation or configuration
Deployment is streamlined through scan-and-go mobile provisioning, allowing installers to power the device, scan a QR code, and bring the controller online with minimal or no manual configuration.
Impact & Outcomes
Delivered a turnkey intelligent edge controller for industrial IoT and predictive maintenance use cases
Enabled local rule execution with sub-second response times independent of cloud round-trips
Reduced LoRaWAN network traffic by over 99% through edge-based filtering and aggregation
Eliminated site visits through remote Modbus polling, configuration, and rule updates
Enabled retrofit of legacy industrial sensors without replacing existing field equipment
Successfully transitioned the platform from low-volume startup production to scaled manufacturing at Digi
Technical Scope & Ownership
System Architecture: End-to-end IEC architecture spanning hardware, firmware, edge logic, and cloud integration
MCU Platform: Silicon Labs EFR32 running FreeRTOS
Wireless Connectivity: Digi XBee-LR LoRaWAN module (US915 / EU868)
Edge Intelligence: Local rule engine supporting up to 80 concurrent edge rules with sub-second evaluation
Industrial Interfaces:
Modbus RTU (RS-485)
Analog inputs (4–20 mA, voltage)
Digital I/O and latching relay outputs
Provisioning: QR-based scan-and-go provisioning with cloud-managed device templates
Cloud Integration: Digi X-ON platform for configuration, monitoring, rule management, and OTA updates
Power Architecture: External DC input or internal long-life lithium battery supporting multi-year operation
Security: Secure provisioning, encrypted communications, and controlled configuration surfaces
Production Readiness: Regulatory certification, lifecycle management, and long-term support
Platform Capabilities
Typical LoRaWAN range up to 15 km (10 miles)
On-demand cloud polling and configuration of Modbus registers
Sub-second local monitoring and alarm generation
Local edge processing with unlimited cloud-based rule extensions
Remote configuration updates without site visits
Designed for industrial monitoring and predictive maintenance deployments
Ecosystem Alignment
The XBee Intelligent Edge Controller serves as the edge intelligence layer within Digi’s broader LoRaWAN ecosystem:
Digi XBee-LR for long-range, low-power device connectivity
Digi HX15 / HX20 gateways for scalable LoRaWAN infrastructure
Digi X-ON for unified device-to-cloud management
Together, these platforms form a cohesive device → controller → gateway → cloud architecture for industrial IoT deployments.
References
Digi XBee Intelligent Edge Controller Product Page
https://www.digi.com/products/embedded-systems/digi-x-on/digi-xbee-intelligent-edge-controller