Selected Hardware & Firmware Engineering Projects
Real-world systems designed, coded, bench-validated, and delivered to production by Aarohi Tech Lab.
Kon-Tiki Flame-Cap Biochar Kiln IoT Sensor System
Industrial high-temperature pyrolysis monitoring system built for authentic flame-cap biochar kilns. Features precision thermocouple telemetry, real-time wireless transmission, single core probe architecture with optional dual probe expansion, and compliance with leading carbon credit verification standards.
- Ruggedized thermocouple signal conditioning for extreme thermal zones
- Single core temperature probe standard with optional second probe support
- Encrypted wireless telemetry for remote logging outside hazardous heat perimeters
- Compliant with major carbon credit registries and verification bodies
ESP32-S3 Industrial Cloud Telemetry & Modbus Gateway
High-throughput dual-core edge gateway interfacing factory PLCs via Modbus RTU/TCP (RS-485/Ethernet) and streaming encrypted telemetry to AWS IoT Core with zero packet loss under network dropouts.
- Dual-partition fail-safe OTA with cryptographic firmware signature check
- Hardware-accelerated AES-256 and X.509 mTLS certificate authentication
- Local circular buffer in non-volatile flash storing up to 72 hours of offline telemetry
- Automated watchdog recovery with hardware brownout detection
STM32 TouchGFX / LVGL Medical & Industrial HMI
Full-color capacitive touchscreen interface delivering 60fps animations on STM32 microcontrollers. Decoupled FreeRTOS architecture ensures instantaneous touch feedback while running real-time control loops in the background.
- Hardware-accelerated Chrom-ART (DMA2D) rendering with double-buffered framebuffers
- Multi-language dynamic typography and custom vector icon rendering
- Resistive and capacitive touch controller drivers over I2C/SPI
- Zero UI latency with asynchronous message queues connecting control threads
Nordic nRF52840 Ultra-Low-Power BLE 5.2 Sensor Beacon
Sub-15µA average sleep current asset monitoring tag with accelerometer-based wake-on-motion, environmental temperature/humidity sensors, and custom Bluetooth Low Energy GATT service.
- Dynamic advertising intervals with Bluetooth 5.0 Long Range (Coded PHY)
- Deep sleep optimization with DC-DC regulator mode and optimized peripheral clocks
- Secure peer bonding with AES-CCM hardware crypto
- Android and iOS companion app pairing with over-the-air DFU bootloader
Three-Phase Smart Motor Protection & Power Analyzer
Microcontroller-driven motor protection unit measuring true RMS current, voltage, phase asymmetry, under/over-voltage, and earth leakage, preventing catastrophic motor winding burnout.
- True RMS sampling with 16-bit ADC oversampling algorithms
- Definite time and inverse definite minimum time (IDMT) trip curves
- Isolated RS-485 Modbus telemetry with event logging and trip history
- Ruggedized TVS surge, EFT, and ESD protection compliant with IEC industrial standards
High-Speed 4-Layer Altium Hardware & Impedance-Controlled PCB
Turnkey multi-layer PCB design featuring RF antenna impedance matching, clean digital-to-analog partition grounds, low thermal resistance, and full DFM certification for automated SMT assembly.
- 50Ω single-ended and 100Ω differential controlled impedance routing
- Optimized 4-layer stackup: Signal - Ground - Power - Signal
- Thermal relief vias under high-current buck converters and power MOSFETs
- Complete manufacturing pack: Gerbers (RS-274X), drill charts, IPC netlist, BOM
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