Projects & Case Studies
Anonymized engineering deliverables: Problem, Solution, Deliverables, and Measurable Outcomes
Strict NDA & Intellectual Property Protection
Client names and proprietary details are anonymized. 100% of source code, Gerbers, and IP transfer exclusively to our clients upon final payment.
High-Efficiency Motor Drive & Inverter Control Board
High EMI noise triggering false fault trips during high-load switching; thermal throttling at 45°C ambient.
- •Redesigned gate driver loop layout to minimize parasitic inductance and dv/dt spikes.
- •Implemented dead-time compensation in STM32 timer hardware registers.
- •Built 4-layer PCB with dedicated ground planes and optimized thermal vias.
Schematic & Gerber package (Altium), firmware source with FreeRTOS, full validation report.
STM32G4 · FOC / PWM · 4-Layer PCB · EMI Mitigation
Turnkey EV Charger Controller & Safety Interlock Gateway
Intermittent control pilot (CP) signal jitter under noisy commercial charging environments; strict IEC 61851 safety interlock timing.
- •Designed analog comparator circuit with hardware hysteresis and surge clamping.
- •Implemented deterministic FreeRTOS state machine with <10ms contactor trip response.
- •Integrated isolated RS-485 Modbus link to MID-certified revenue meters.
Full PCB design package (Gerbers, ODB++, iBOM), FreeRTOS C source, hardware test suite.
ISO 15118 / OCPP · CAN Bus · FreeRTOS · MID Metering
ESP32-S3 Industrial IoT Gateway with Modbus RTU
Field lockups and memory fragmentation during OTA updates over intermittent cellular and Wi-Fi networks in factories.
- •Architected dual-bank flash partition with cryptographic signature validation and rollback.
- •Engineered isolated RS-485 transceiver circuitry with TVS surge protection.
- •Implemented lightweight MQTT over TLS 1.3 telemetry client with localized flash queue buffering.
Altium manufacturing files, ESP-IDF C++ firmware source, AWS IoT Core integration guide.
ESP32-S3 · Modbus RTU · Fail-Safe OTA · AWS IoT Core
Sub-GHz Long-Range Telemetry Link & Remote Sensors
Battery depletion within 6 months due to high RF transmit peaks; signal packet dropouts over 3km undulating terrain.
- •Designed custom pi-network RF impedance matching network for 868MHz / 915MHz ISM bands.
- •Engineered ultra-low power sleep states (<12µA standby current) with RTC timer wakeups.
- •Implemented adaptive frequency hopping (AFH) and forward error correction (FEC).
KiCad 4-layer layout with RF guard ring, bare-metal C firmware, RF range test analysis.
Sub-GHz RF · 868/915 MHz · Ultra-Low Power (<15µA) · KiCad
Multi-Zone Industrial HVAC Variable Speed Controller
Severe compressor startup voltage dips resetting the microcontroller; wide sensor drift across -20°C to +70°C ambient extremes.
- •Integrated wide-input synchronous buck regulator with 4kV surge withstand capability.
- •Implemented digital filtering and factory calibration lookup tables for multi-point thermistors.
- •Engineered modulated PWM fan staging with S-curve ramp acceleration.
Altium layout & schematic, production BOM with AEC-Q qualified components, deterministic firmware.
HVAC Control · BLDC Modulation · Surge Protection · Altium
Production-Line Optical & Sensor Inspection Station
Manual QA inspection causing a 2-minute bottleneck per circuit board assembly; human error missing micro-soldering bridges.
- •Engineered automated test fixture with high-speed digital camera and laser profiling sensors.
- •Built STM32-driven stepper gantry system with Saleae-verified fast serial data ingestion.
- •Automated pass/fail logging integrated directly into factory ERP database.
Custom test fixture PCB, mechanical mount CAD, sensor calibration firmware, Python daemon.
Production QC · Sensor Fusion · High-Speed Serial · Test Jigs
Motor control algorithms, dual-band telemetry nodes, battery management systems (BMS), and smart sensor gateways — delivered under NDA for international OEM and industrial clients.
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