Challenge

Design a high-power SMPS capable of delivering ±160V or ±200V DC to power four 2,500W audio amplifiers. The original transformer core was unavailable in India.

Solution

Reverse-engineered the original circuit. Adapted a locally-available ferrite core with equivalent performance through careful winding calculations and air gap adjustment. Designed a custom flyback controller using comparators and 555 timers—no off-the-shelf PWM IC.

Outcome

Production units deployed. Powers professional audio installations.

Specifications

Technologies

Protection & Features

• Over-voltage
• Under-voltage
• Over-current
• Output regulation
• Voltage symmetry

Challenge

Build a wireless, battery-powered target retriever for shooting ranges with precise positioning, real-time status reporting, and integration with range management software.

Solution

Designed end-to-end: BLDC motor control with field-oriented control, quadrature encoder for position feedback, Hall sensors for zero-position detection, ESP32 for MQTT-based communication, and a complete Windows application in Python/PySide6 for range control.

Outcome

Complete product line delivered. Hardware, firmware, desktop software, and API.

Specifications

Technologies

Protection & Features

• Closed-loop position control
• Configurable acceleration/deceleration
• Battery management

Challenge

Create an industrial-grade 3-phase power monitoring system with true RMS measurement, local display, and cloud connectivity—deployed at minimal cost.

Solution

ATmega handles precision measurement and 30-digit multiplexed display. ESP32 provides MQTT connectivity. AWS Lightsail ($5/mo) hosts the broker with TLS, user authentication, and historical data. Local web server provides configuration and real-time display.

Outcome

Production deployment. Real-time monitoring across multiple sites.

Specifications

Technologies

Protection & Features

• Window comparator
• Relay control
• Event logging
• User authentication