Magnetic Crawler Robot Control System -- 2

Project Requirement: Remote-Controlled Magnetic Crawler – Control System Development
Objective:
I am developing a magnetic crawler robot that can operate on ferrous surfaces, including vertical walls. The crawler hardware (frame, motors, power supply, etc.) will be purchased and assembled at my location.
I require an experienced robotics/electronics/control engineer who can finalize the control system design (hardware + software), provide complete details for purchase and assembly, and offer support during trials. If issues are identified during testing, the engineer must suggest and provide corrections (hardware/software), which I will then implement and re-test.
Scope of Work:
1. Control System Design
• Remote control operation (wired prototype,).
• Selection and integration of motor control method:
a) DC motor + H-bridge driver (e.g., BTS7960).
b) Stepper motor + driver (if holding torque required).
c) BLDC + ESC (optional for smoother control).
• Provide pros/cons comparison to finalize selection.
2. Control Interface
• Wired remote control (joystick + toggle switches).
• Microcontroller-based control (Arduino / STM32 / ESP32).
• Provision for upgrade to wireless (RF/LoRa/Bluetooth).
3. Power Input & Output
• Power input must support dual AC supply options: 220V or 440V (any one can be used depending on site).
• DC power output to be designed as per crawler requirements (voltage/current rating to be specified by engineer).
• Include overload protection, fuses, and safety interlocks.
4. Programming & Electronics
• Microcontroller programming (PWM, direction, logic).
• Motor driver control code.
• Emergency stop and safety logic.
• Modular, expandable code (sensors, wireless, camera can be added later).
5. Safety & Feedback Systems
• Emergency kill switch inline with power.
• Limit sensors / bump switches for safety.
• Current sensing for overload detection.
6. Support & Corrections
• Engineer to provide:
a) Detailed wiring diagrams and block diagrams.
b) Programming code with comments.
c) Component selection details (motors, drivers, power units, etc.).
• After I assemble and test:
a) If any issue arises, engineer must analyze test results and provide corrections (software/hardware).
b) I will apply changes locally and repeat trials.
Deliverables:
• Finalized control system design with options and recommendations.
• Microcontroller programming files.
• Wiring diagrams, block diagrams, and assembly details.
• Correction support after first trial until system works reliably.
What I have:
• Mechanical crawler hardware (chassis, wheels, power).
• Purchase and assembly of recommended components.
• Testing at my site and sharing results with the engineer.
Expectations:
• Provide clear guidance for purchase and assembly.
• Support through trial-and-error corrections until crawler is functional.
• Ensure design is safe, reliable, and expandable.
• Must handle dual AC input (220V/440V) with DC output as per crawler needs.
Target Freelancer Profile:
• Robotics / Mechatronics / Electronics Engineer with experience in:
a) Motor drivers and controllers (DC, Stepper, BLDC).
b) Arduino / STM32 / ESP32 programming.
c) Remote control (wired/wireless).
d) Power electronics (220/440V AC to DC conversion).
e) Safety system design.