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Madhava H S's avatar
Madhava H S
Sidlaghatta, India
IoT & Embedded Systems Engineer ESP32, Raspberry Pi, Sensors
New to Contra
IoT & Embedded Systems Engineer ESP32, Raspberry Pi, Sensors
Cover image for Title: FlowSense Pro -
Title: FlowSense Pro - Industrial Flow & Chemical Dosing SCADA Gateway with OPC-UA & BLE Problem: Municipal wastewater treatment plants, breweries, and chemical processing facilities rely on analog 4–20 mA pressure/flow transmitters and mechanical pulse flow meters that lack native network connectivity. Modernizing these field instruments into SCADA platforms historically required dedicated automation racks and programmable logic controllers, inflating per-station deployment costs. Additionally, field technicians in wet, hazardous environments struggle with device commissioning and routine calibration because older systems require physical laptops, terminal blocks, and USB-to-serial cables. Traditional field gateways also lack secure, fail-safe remote firmware updates (OTA), risking operational downtime during software maintenance. Solution: Built a ruggedized, DIN-rail mounted smart gateway around the ESP32-S3 (Xtensa dual-core 240MHz) utilizing ESP-IDF v5.x: High-Precision Dual Measurement: Combines a 16-bit ADS1115 ADC and a 0.1% precision 100 Ω shunt to read 4–20 mA current loops with ±0.5% calibrated accuracy, alongside a hardware pulse counter (PCNT) interrupt engine reading turbine flow meters up to 500 L/min. Direct SCADA & OPC-UA Integration: Compiles the open-source open62541 OPC-UA stack directly into ESP-IDF, enabling the gateway to communicate natively with SCADA servers and industrial HMIs over TCP/IP without intermediate PLC hardware. Cable-Free BLE Commissioning: Implements a custom BLE 5.0 GATT profile that allows field operators to calibrate sensor K-factors, set alarm thresholds, and configure local Wi-Fi credentials via an iOS/Android mobile companion app in seconds. Zero-Power Display & Fail-Safe Actuation: Integrates an ultra-low-power 2.9" SPI E-Paper display that maintains critical process readouts even during brownouts, alongside four opto-isolated 24V/3.5A power MOSFET outputs driving dosing pumps and emergency shutoff valves in <10 ms. Enterprise Security & Robust OTA: Employs mutual-TLS (mTLS) certificate-based authentication with AWS IoT Core and dual-partition HTTPS OTA with automated bootloader rollback upon boot failure.
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Cover image for Title: Smart Assistive Gesture Glove
Title: Smart Assistive Gesture Glove and Caretaker Alert System 1. Problem statement: Speech-impaired, partially paralyzed, or bedridden patients often struggle to communicate basic necessities (food, water, washroom, physical discomfort) or call for immediate emergency help without a caregiver continuously in the room. Standard push-button call systems lack expressive nuance, while cloud-reliant smart devices fail completely whenever local Wi-Fi or internet connectivity drops, posing a critical safety hazard during medical emergencies. 2. Solution and Technical Implementation: ​Gesture-to-Intent Recognition: The patient wears a wearable glove equipped with four flex sensors. Using trimmed-mean signal sampling and Exponential Moving Average (EMA) filtering, the system filters out muscle tremors and maps individual finger flexes to primary needs (Food, Washroom, Water, Discomfort), with a chorded fist gesture reserved for an instant Emergency SOS. ​Zero-Downtime Local Transmission: Communication between the glove and the caregiver base station uses peer-to-peer ESP-NOW radio protocol. This operates completely independent of routers or internet access, featuring an auto-channel hopping algorithm on the glove to maintain the radio link even if radio channels shift. ​Multi-Modal Feedback & Cloud Alerts: The receiver base station converts incoming packets into immediate spoken voice alerts via a DFPlayer Mini MP3 module, visually displays the request on an SSD1306 OLED, and sounds an active buzzer during SOS events. ​Non-Blocking Remote Gateway: An asynchronous FreeRTOS background task pinned to Core 0 relays every command and glove-disconnection warning directly to the caregiver’s smartphone via a Telegram Bot, ensuring family members stay informed even when away from the base station without delaying real-time local alarms.
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Cover image for Title: SmartMill Guardian - CNC
Title: SmartMill Guardian - CNC Machine Predictive Health & Vibration Diagnostics Edge System Problem statement: High-precision CNC milling centers and industrial machining tools frequently suffer from sudden spindle bearing degradation and thermal runaway. A single unplanned spindle seizure costs manufacturing facilities upwards of $40,000 per incident in damaged workpieces, emergency tooling, and shop-floor downtime. Traditional plant maintenance relies on manual spot checks every 4 to 8 hours or cloud-only IoT gateways that suffer from 2–5 second network latencies—far too slow to trigger an emergency feed-hold before catastrophic mechanical failure. Furthermore, retrofitting older factory machinery with proprietary PLC hardware (e.g., Siemens S7 racks) is prohibitively expensive and requires disruptive rewiring. Solution: Designed and deployed a deterministic edge monitoring unit powered by a Raspberry Pi 4B running bare-metal FreeRTOS and Embedded C (C99): High-Rate Vibration FFT: Interfaces with an ADXL345 3-axis MEMS accelerometer via hardware SPI at 1 kHz ODR. An on-chip CMSIS-DSP Fast Fourier Transform (FFT) paired with a lightweight µTensor INT8 model identifies bearing defect frequencies (BPFO/BPFI harmonics) with 94% accuracy. Thermal Profiling & PLC Bridging: Continuously monitors bearing temperatures using an MLX90614 infrared sensor over I²C while polling spindle speed, drive current, and status words from existing Siemens S7-1200 PLCs over RS-485 Modbus RTU. Deterministic Emergency Interlock: Features a 4-channel opto-isolated relay interface capable of triggering a CNC machine feed-hold or spindle stop in <5 ms upon anomaly detection—eliminating cloud latency. Cloud & SCADA Telemetry: Securely streams time-series vibration metrics and alerts via TLS 1.3 MQTT to AWS IoT Core, populating live shop-floor InfluxDB and Grafana dashboards for condition-based maintenance scheduling.
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Cover image for Title: Industrial IoT Environmental Monitor,
Title: Industrial IoT Environmental Monitor, OLED HUD & Actuator Node Description: An autonomous edge-computing IIoT monitoring and safety node built using an ESP32 microcontroller. The system tracks real-time environmental metrics and executes local automation logic with zero cloud latency. Key features: 1. Multi-Sensor Telemetry: Integrates a BME280 sensor for ambient temperature, humidity, and barometric pressure alongside an MQ-135 sensor for real-time air quality and gas detection. 2. Local OLED HUD Dashboard: Features an SSD1306 OLED display to provide operators with crystal-clear, on-site visual diagnostics and live system status updates. 3. Autonomous Edge Actuation: Automatically triggers an opto-isolated relay (M281) and piezo buzzer to drive ventilation fans and warning alarms when safety thresholds are breached. 4. Optimized Firmware: Powered by clean C/Arduino code utilizing hardware I2C communication, analog data mapping, and robust Active-LOW relay control logic.
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Adrian Pratt's avatar
Adrian Pratt
Tanza, Philippines
Game Design & Data Visualization Expert 🌟
Game Design & Data Visualization Expert 🌟
Cover image for Physical Product Simulator
Physical Product Simulator
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Cover image for Custom Extruder carriage for 3D Printer
Custom Extruder carriage for 3D Printer
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Cover image for Vacuum cleaner powered spinning brush mount
Vacuum cleaner powered spinning brush mount
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Cover image for Customizable Magnetic Pegboard SCAD design
Customizable Magnetic Pegboard SCAD design
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Satheesh Yesudhas's avatar
Satheesh Yesudhas
Kalyan, India
Expert 3D Models for Precision Manufacturing
Expert 3D Models for Precision Manufacturing
Cover image for High-Precision 3D Printed Component Design
High-Precision 3D Printed Component Design
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Cover image for I will design 3D Sheet Metal and 2D drawings for manufacturing
I will design 3D Sheet Metal and 2D drawings for manufacturing
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Cover image for Comprehensive Plastic Components Design Project
Comprehensive Plastic Components Design Project
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Hange Zoe's avatar
Hange Zoe
Amman, Jordan
Robotics Engineer | Embedded Systems Developer
New to Contra
Robotics Engineer | Embedded Systems Developer
Cover image for I designed and built a
I designed and built a custom four-wheel rover powered by an ESP32 and four high-speed motors. The project included motor control, electronic integration, programming, and the development of the complete rover system.
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Cover image for I designed and programmed multiple
I designed and programmed multiple autonomous line follower robots for robotics competitions and educational projects. The work involved sensor calibration, PID control, motor control, and optimizing the robot's speed and stability to achieve accurate line tracking and fast performance.
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Cover image for Autonomous Sumo Robots for HTU Sumo Contest
Autonomous Sumo Robots for HTU Sumo Contest
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Cover image for I designed and developed a
I designed and developed a custom robot for the WRO Senior 2024 competition. The project involved building and programming an autonomous robot to complete competition tasks, with a focus on mechanical design, sensors, motor control, and autonomous navigation.
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Chris Fuchser's avatar
Chris Fuchser
Tucson, USA
Creator, YouTube Producer, Project Manager, Engineer
Creator, YouTube Producer, Project Manager, Engineer
Cover image for Bespoke Marble Run Built for Client's Expo Booth in Las Vegas
Bespoke Marble Run Built for Client's Expo Booth in Las Vegas
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Cover image for Marble Engineering Invention Video (1M views)
Marble Engineering Invention Video (1M views)
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Cover image for Sponsored Marble Run Video (1.6M views)
Sponsored Marble Run Video (1.6M views)
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FATHIMA JASMIN's avatar
FATHIMA JASMIN
Bhavani, India
AI & ML expert fusing data science with creative design.
AI & ML expert fusing data science with creative design.
Cover image for AI Designed Bot
AI Designed Bot
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Cover image for AI Front end and tinkercad circuit
AI Front end and tinkercad circuit
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Cover image for Digital twin
Digital twin
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