ESP32-Based 18V / 5000A DC Rectifier Monitoring System – Industrial Grade (India Only)

Need a complete hardware + firmware design for a 0–18V/0-36V, 0–5000A DC rectifier monitoring system using ESP32-WROOM. The system must accurately measure voltage and current (±2%), log data to SD card with RTC timestamps, display readings on LCD, and operate 24 hrs on battery backup with full electrical protection. Core Requirements: Controller: ESP32-WROOM (Wi-Fi AP/STA selectable via slide switch) Module (Connect via header 38 pin) Measurement: Dual shunt inputs Port 1 – 0-100 mV (voltage-type shunt) INA226 Port 2 – 0-100 mA (current-type shunt) INA226 share with port1 using switch selection Firmware-selectable & polarity configurable (High/Low type) shunt-to-current mapping Voltage range 0–18V DC and 0-36V DC Accuracy ±2 % Display & Controls: 1602 LCD + 5 switches (1 analog port, debounced) + Reset button (NO I2C) Digital I/O: 4 IN + 4 OUT (opto-isolated with LEDs) 12V/5V selectable OUT (DIP) Analog I/O: 2 IN (0–10 V via IC ADC 12-bit) INA226 + 2 OUT (0–10 V clean DC DAC) GP8403 Storage: microSD card + RTC (with battery backup) Power: 220 V AC → HiLink DC converter Battery Backup: 24 hr Li-ion + BMS (ESP32 monitors voltage & mode) BQ24074 Electrical Protections (Required): Input: reverse-polarity, over-voltage, over-current, surge, ESD Output: short-circuit, overload, isolation on opto lines Power: surge, reverse, thermal, fuse protection Battery: over-charge/discharge & status feedback Deliverables: Full schematic + PCB layout (2 layer) BOM with India-available parts Working prototype + Enclosure + test code & video 3D Enclosure STL and STEP files Who Should Apply: Indian embedded engineers / hardware developers only Proven work with ESP32, precision analog circuits, and industrial protection design Must deliver a tested prototype To Apply Please include: Short approach + ICs you plan to use Estimated cost & timeline Links or photos of previous ESP32 / industrial control projects

ID do Projeto: 39937455