THE CHALLENGE
Custom embedded hardware for multi-protocol industrial data acquisition in harsh environments (−40°C to 85°C, high EMI).
THE SOLUTION
ESP32-based hardware with isolated RS-485, CAN, and Ethernet interfaces. EMI-hardened PCB layout, conformal coating, DIN rail mounting mechanical design.
RESULTS & OUTCOMES
Multi-site industrial deployment
-40°C to 85°C operating range validated
IEC 61326 EMC compliance
2-year field operation without hardware failures
This project developed a ruggedised IoT gateway for multi-site industrial data acquisition across India. The hardware needed to operate reliably in substation environments with high EMI, wide temperature swings, and minimal maintenance access.
Hardware Architecture
The ESP32 dual-core SoC provides the processing and wireless connectivity backbone. All external interfaces — RS-485, CAN bus, and Ethernet — use galvanic isolation via digital isolators and isolated DC–DC converters, protecting the ESP32 from the elevated common-mode transients present in industrial environments.
PCB Design for Harsh Environments
The four-layer PCB uses a solid ground plane with careful partitioning between digital, analog, and isolated domains. Ferrite beads and LC filters attenuate conducted emissions on power rails. Conformal coating (acrylic, IPC-CC-830B) protects against condensation and particulate contamination. The assembly mounts on a custom DIN rail bracket machined from aluminium extrusion.
Field Performance
Units have operated continuously across multiple industrial sites for over two years without hardware failures. Environmental testing validated operation across the full −40°C to 85°C range, and the design achieved IEC 61326-1 Class A EMC compliance.
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Eight years of production-proven hardware expertise — from first topology decision to regulatory sign-off.