Energy Harvesting ESP32 Current Monitor
Budget: ₹75,000 – ₹150,000 INR
Project Title: Expert Electronics Engineer for Energy Harvesting & Charging Circuit for ESP32-based IoT Monitor
Category: Engineering & Technical > Electronics Engineering, Circuit Design, PCB Layout
Keywords: Energy Harvesting, Circuit Design, PCB Layout, Power Electronics, ESP32, IoT, Battery Charging, Current Transformer (CT)
Project Overview
We are an IoT company that has developed a functional prototype of a multi-phase, battery-powered energy monitor. Our goal is to make this device fully self-sustaining by designing an add-on energy harvesting circuit that continuously charges the onboard battery. We are looking for an expert electronics engineer to partner with us to design, prototype, and deliver this critical subsystem.
About Our Current Prototype
To provide clear context, here is the status of our existing device:
Microcontroller: Seeed Studio Xiao ESP32-S3.
Power Source: Standard 18650 Li-ion battery (2600mAh).
Current Performance: The device is highly optimized for low power consumption. Using the ESP32's deep sleep cores and optimized firmware, it can run for approximately 30 days on a single charge.
Sensing Method: It uses up to three SCT-013-060 (60A/1V) current transformers to sense current on residential power lines. The CTs connect via standard 3.5mm audio jacks.
Analog Front-End: We use an external Analog-to-Digital Converter (ADS) for precise current measurement.
Firmware: The firmware, connectivity (WiFi), and cloud integration are already handled by our internal team.
The Core Task: Your Mission
Your primary responsibility will be to design a complete energy harvesting and battery charging circuit that can be integrated with our existing prototype. The goal is to make the device operate perpetually without needing a manual recharge.
Your scope of work will include:
Circuit Design & Schematic:
Design a robust circuit that harvests energy from a current transformer (CT) placed on a 230V, 50Hz AC line carrying 20-100A.
The circuit must efficiently convert the harvested energy and use it to charge the onboard 18650 Li-ion battery.
You will propose the optimal approach:
Option A: Harvest energy from the existing SCT-013-060 sensing CTs without interfering with the sensitive measurement signals going to the ADS.
Option B: Use a separate, dedicated CT clamp solely for energy harvesting.
The design must include a proper Li-ion battery management system (BMS) with over-charge, over-discharge, and short-circuit protection.
Component Selection & Bill of Materials (BOM):
Select cost-effective, reliable, and readily available components.
Provide a detailed BOM, including part numbers and potential suppliers, with an eye on keeping the additional cost minimal.
PCB Layout & Design:
Create a compact and efficient PCB layout for the designed circuit.
The PCB should be designed as a small "daughterboard" or module that can be easily integrated into our existing product enclosure.
Deliver complete Gerber files for manufacturing.
Prototyping & Testing:
Assemble and deliver one or two functional, tested prototypes of the energy harvesting board.
Provide documentation on how to integrate and test the prototype with our main ESP32-S3 board.
Key Technical Challenges to Address in Your Proposal
Low Current Harvesting: The circuit must be able to harvest meaningful energy even at lower household current levels (e.g., below 10A).
Signal Integrity: If pursuing Option A, a key challenge is to prevent the harvesting circuit from introducing noise or otherwise corrupting the precise measurements from the sensing CTs.
Efficiency vs. Cost: Balancing the power conversion efficiency with the component cost.
Safety: The design must incorporate all necessary safety features for a device connected to mains electricity.
What We Will Provide
Full schematics and documentation for our existing ESP32-S3 prototype.
A physical prototype unit for your integration and testing purposes.
Detailed information on the device's power consumption profile (active and sleep modes).
Direct access to our engineering team for questions and collaboration via Slack/email.
Ideal Candidate Profile
Proven experience in analog and power electronics circuit design.
Demonstrable experience with energy harvesting circuits is a must-have.
Strong background in Li-ion battery charging and management (BMS) circuits.
Proficient in PCB design software (e.g., KiCad, Altium, Eagle).
Experience with current transformers and IoT device design is a significant plus.
Excellent communication skills and a collaborative mindset.
The budget and timelines can be discussed further later once we have a quotation from you on this.
Category: Engineering & Technical > Electronics Engineering, Circuit Design, PCB Layout
Keywords: Energy Harvesting, Circuit Design, PCB Layout, Power Electronics, ESP32, IoT, Battery Charging, Current Transformer (CT)
Project Overview
We are an IoT company that has developed a functional prototype of a multi-phase, battery-powered energy monitor. Our goal is to make this device fully self-sustaining by designing an add-on energy harvesting circuit that continuously charges the onboard battery. We are looking for an expert electronics engineer to partner with us to design, prototype, and deliver this critical subsystem.
About Our Current Prototype
To provide clear context, here is the status of our existing device:
Microcontroller: Seeed Studio Xiao ESP32-S3.
Power Source: Standard 18650 Li-ion battery (2600mAh).
Current Performance: The device is highly optimized for low power consumption. Using the ESP32's deep sleep cores and optimized firmware, it can run for approximately 30 days on a single charge.
Sensing Method: It uses up to three SCT-013-060 (60A/1V) current transformers to sense current on residential power lines. The CTs connect via standard 3.5mm audio jacks.
Analog Front-End: We use an external Analog-to-Digital Converter (ADS) for precise current measurement.
Firmware: The firmware, connectivity (WiFi), and cloud integration are already handled by our internal team.
The Core Task: Your Mission
Your primary responsibility will be to design a complete energy harvesting and battery charging circuit that can be integrated with our existing prototype. The goal is to make the device operate perpetually without needing a manual recharge.
Your scope of work will include:
Circuit Design & Schematic:
Design a robust circuit that harvests energy from a current transformer (CT) placed on a 230V, 50Hz AC line carrying 20-100A.
The circuit must efficiently convert the harvested energy and use it to charge the onboard 18650 Li-ion battery.
You will propose the optimal approach:
Option A: Harvest energy from the existing SCT-013-060 sensing CTs without interfering with the sensitive measurement signals going to the ADS.
Option B: Use a separate, dedicated CT clamp solely for energy harvesting.
The design must include a proper Li-ion battery management system (BMS) with over-charge, over-discharge, and short-circuit protection.
Component Selection & Bill of Materials (BOM):
Select cost-effective, reliable, and readily available components.
Provide a detailed BOM, including part numbers and potential suppliers, with an eye on keeping the additional cost minimal.
PCB Layout & Design:
Create a compact and efficient PCB layout for the designed circuit.
The PCB should be designed as a small "daughterboard" or module that can be easily integrated into our existing product enclosure.
Deliver complete Gerber files for manufacturing.
Prototyping & Testing:
Assemble and deliver one or two functional, tested prototypes of the energy harvesting board.
Provide documentation on how to integrate and test the prototype with our main ESP32-S3 board.
Key Technical Challenges to Address in Your Proposal
Low Current Harvesting: The circuit must be able to harvest meaningful energy even at lower household current levels (e.g., below 10A).
Signal Integrity: If pursuing Option A, a key challenge is to prevent the harvesting circuit from introducing noise or otherwise corrupting the precise measurements from the sensing CTs.
Efficiency vs. Cost: Balancing the power conversion efficiency with the component cost.
Safety: The design must incorporate all necessary safety features for a device connected to mains electricity.
What We Will Provide
Full schematics and documentation for our existing ESP32-S3 prototype.
A physical prototype unit for your integration and testing purposes.
Detailed information on the device's power consumption profile (active and sleep modes).
Direct access to our engineering team for questions and collaboration via Slack/email.
Ideal Candidate Profile
Proven experience in analog and power electronics circuit design.
Demonstrable experience with energy harvesting circuits is a must-have.
Strong background in Li-ion battery charging and management (BMS) circuits.
Proficient in PCB design software (e.g., KiCad, Altium, Eagle).
Experience with current transformers and IoT device design is a significant plus.
Excellent communication skills and a collaborative mindset.
The budget and timelines can be discussed further later once we have a quotation from you on this.
Related categories:
Engineering
Electronics
Matlab and Mathematica
Electrical Engineering
Telecommunications Engineering