🔧 Available for Freelance · Industrial IoT Specialist

I Build Industrial
Embedded Systems
That Scale

Firmware engineer crafting production-grade IoT solutions with Raspberry Pi, ESP32, and real-time control systems for industrial clients worldwide.

View Projects 📐 Cirkit Schematics (B&W CAD) Hire Me on Contra
50+
IoT Devices Deployed
3
Industrial Projects
99.7%
System Uptime
5★
Client Rating
Featured Work

Industrial-Grade Projects

Three high-complexity embedded systems projects built for real-world industrial environments.

🫐
● Raspberry Pi 4 · Embedded C · RTOS · Industrial IoT

SmartMill Guardian — CNC Machine Health Monitoring System

A real-time predictive maintenance platform for industrial CNC machines, using vibration analysis, thermal profiling, and anomaly detection to prevent costly downtime.

Core Features
  • Real-time vibration FFT analysis via ADXL345 accelerometer (bare-metal SPI in C)
  • Thermal profiling with MLX90614 IR sensor — detects bearing overheating
  • Preemptive RTOS scheduler (FreeRTOS on bare metal RPi4) for deterministic sampling
  • MQTT broker (Mosquitto) publishing 1 kHz sensor packets to AWS IoT Core
  • Anomaly detection model (µTensor) running on-device — no cloud latency
  • 4-relay output board for automated machine shutdown on fault detection
  • 7-inch industrial touchscreen HMI (framebuffer, no X11) for shop-floor operators
  • RS-485 Modbus RTU master — integrates with Siemens PLC ecosystem
System Architecture
┌─────────────────────────────┐ │ Raspberry Pi 4 (Bare C) │ ├──────────────┬──────────────┤ │ SPI: ADXL345 │ I²C: MLX90614│ │ UART: Modbus │ GPIO: Relays │ ├──────────────┴──────────────┤ │ FreeRTOS Task Scheduler │ │ FFT Engine · µTensor ML │ ├─────────────────────────────┤ │ MQTT → AWS IoT Core │ │ Grafana Dashboard (Cloud) │ └─────────────────────────────┘
Tech Stack
Embedded C (C99) FreeRTOS Raspberry Pi 4B SPI / I²C / UART Modbus RTU MQTT / Mosquitto AWS IoT Core µTensor ML FFT (CMSIS-DSP) Grafana InfluxDB Python (config tooling)
Deliverables
  • Complete firmware source (CMake, GCC cross-compile)
  • Hardware schematic (KiCad) + BOM for 50-unit production
  • AWS CDK infrastructure stack for cloud pipeline
  • Grafana dashboard JSON templates
  • Operator manual + calibration procedure
Performance Results
1kHz
Sample Rate
<5ms
Fault Latency
94%
ML Accuracy
60%
Downtime Cut
Starting at \$490 · 2–3 weeks
View Case Study → 📐 Cirkit CAD (B&W) Hire for This
⚡
● ESP32-S3 · FreeRTOS · Wi-Fi · BLE · Edge AI

FlowSense Pro — Industrial Liquid Flow Monitoring & SCADA Gateway

A multi-sensor ESP32-based SCADA gateway that monitors flow rates, pressure, and chemical dosing for water treatment plants and food-grade production lines.

Core Features
  • Pulse-counting flow meter interface (interrupt-driven, debounced) — ±0.5% accuracy
  • 4–20 mA industrial current loop ADC (ADS1115 external ADC via I²C)
  • OPC-UA client over TCP — direct SCADA integration without PLC middleware
  • BLE 5.0 commissioning app (custom GATT profile) — configure without Wi-Fi
  • TLS 1.3 mutual-auth MQTT with AWS IoT Core certificate rotation
  • Over-The-Air (OTA) firmware updates with rollback on boot failure
  • E-Paper display for local readings — zero power when static
  • Edge alarm logic: triggers relay on threshold breach in <10 ms
System Architecture
┌─────────────────────────────┐ │ ESP32-S3 Gateway │ ├──────────────┬──────────────┤ │ PULSE: Flow │ I²C: ADS1115 │ │ RS-485 UART │ SPI: E-Paper │ ├──────────────┴──────────────┤ │ FreeRTOS · LwIP Stack │ │ OPC-UA Client · Alarm Eng │ ├─────────────────────────────┤ │ Wi-Fi → MQTT/TLS → Cloud │ │ BLE → Mobile Commissioning │ └─────────────────────────────┘
Tech Stack
ESP-IDF v5.x ESP32-S3 FreeRTOS OPC-UA (open62541) BLE GATT MQTT / TLS 1.3 AWS IoT Core 4–20 mA ADC OTA Updates E-Paper SPI KiCad PCB Node-RED
Deliverables
  • ESP-IDF firmware (C) with unit tests (Unity framework)
  • 4-layer PCB design — EMI-hardened for industrial enclosures
  • Mobile companion app (Flutter BLE commissioning UI)
  • Node-RED SCADA dashboard + OPC-UA config
  • Compliance docs: IEC 61508 SIL-1 checklist
Performance Results
±0.5%
Flow Accuracy
<10ms
Alarm Response
32
Sensor Nodes
5yr
Battery Life
Starting at \$390 · 1–2 weeks
View Case Study → 📐 Cirkit CAD (B&W) Hire for This
🌐
● ESP32-C6 · Zigbee · Matter · Mesh Network · Smart Factory

MeshForge — Wireless Sensor Mesh for Smart Factory Asset Tracking

A self-healing, 200-node wireless mesh network for smart factory environments — tracking assets, environmental conditions, and energy consumption across a 10,000 m² facility.

Core Features
  • ESP32-C6 native Zigbee stack — IEEE 802.15.4 mesh with auto-healing
  • Matter 1.2 protocol stack — interoperability with AWS Greengrass & Google Home
  • Ultra-wideband (UWB DW1000) ranging — 10 cm asset location accuracy
  • DHT22, CO₂ (SCD41 I²C), and energy meter (CS5490) per node
  • Deep-sleep duty cycling — 2 µA idle draw, 5-year AA battery life
  • Coordinator node: ESP32-S3 with LTE Cat-M1 fallback (SIM7080G)
  • Edge inference: TFLite Micro occupancy model reduces false alarms 80%
  • Secure boot + flash encryption — hardware root of trust (eFuse)
System Architecture
┌─────────────────────────────┐ │ 200× ESP32-C6 Sensor Nodes │ ├──────────────┬──────────────┤ │ Zigbee Mesh │ UWB Ranging │ │ DHT22/SCD41 │ CS5490 Meter │ ├──────────────┴──────────────┤ │ ESP32-S3 Coordinator Hub │ │ Matter 1.2 · TFLite Micro │ ├─────────────────────────────┤ │ LTE Cat-M1 → AWS Greengrass│ │ Web Dashboard · REST API │ └─────────────────────────────┘
Tech Stack
ESP-IDF v5.x ESP32-C6 Zigbee / IEEE 802.15.4 Matter 1.2 UWB (DW1000) TFLite Micro LTE Cat-M1 AWS Greengrass v2 Secure Boot REST API (FastAPI) React Dashboard Docker / K3s
Deliverables
  • Full mesh firmware stack — node, router, and coordinator roles
  • Production PCB with conformal coating (IP54 rated enclosure design)
  • AWS Greengrass Lambda functions + IoT Rules Engine config
  • React-based real-time factory floor map dashboard
  • RF site survey tool + antenna placement guide
Performance Results
200
Node Network
10cm
UWB Accuracy
5yr
Battery Life
80%
False Alarm ↓
Starting at \$540 · 2–4 weeks
View Case Study → 📐 Cirkit CAD (B&W) Hire for This
Expertise

Technical Skills

Deep embedded expertise across hardware, firmware, and cloud — the full IoT stack.

🛠
Embedded C / C++
Expert · 5 years
🫐
Raspberry Pi (bare-metal)
Expert · 4 years
⚡
ESP32 / ESP-IDF
Expert · 4 years
📡
Wireless (BLE / Zigbee / LoRa)
Advanced · 3 years
☁️
AWS IoT Core / Greengrass
Advanced · 3 years
🔌
PCB Design (KiCad)
Advanced · 3 years
⏱
FreeRTOS / RTOS
Expert · 4 years
🤖
TFLite Micro / Edge AI
Intermediate · 2 years
🚀 Ready to Collaborate

Have an Industrial IoT
Project in Mind?

From bare-metal firmware to PCB schematic & cloud pipeline — I build production-ready systems.

✉️ madhavahsmadhav2005@gmail.com

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