Contact person: Universal signal generator

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Location: Bhopal, India

Budget: Recommended by industry experts

Time to start: As soon as possible

Project description:
"USG7007 – Universal Indoor-Outdoor Signal Translator & Diagnostic Tool (Extended Full Specification)


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1. Extended Project Purpose

The USG7007 is not only a translator device but also a universal testing and simulation platform for inverter AC indoor and outdoor PCBs.

It allows engineers to pair mismatched brands (e.g., Daikin indoor with LG outdoor).

It acts as a standalone simulator when one PCB (indoor or outdoor) is missing or faulty.

It provides live diagnostic readings on LCD and app.

It stores logs and profiles for repeat use.

It includes security features (PIN, brand lock, app lock) to prevent unauthorized re-use.



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2. Environmental Requirements

Operating Temperature: 0°C to +55°C (indoor workshop use).

Storage Temperature: –20°C to +70°C.

Humidity: 20% – 90% non-condensing.

Vibration Resistance: Must survive standard transport vibrations.

Conformal Coating: PCB must be coated to resist dust, humidity, and mild corrosion.



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3. Power Supply (More Detail)

AC SMPS must be isolated flyback design with at least 3000 V isolation.

Efficiency >80%.

Protection circuits:

OVP (Over-Voltage Protection).

OCP (Over-Current Protection).

SCP (Short-Circuit Protection).


Indicators: “AC Power OK” and “DC Power OK” messages on LCD.



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4. MCU Requirements (More Detail)

ESP32-WROOM:

Wi-Fi (2.4 GHz) + BLE.

At least 4 MB Flash, 520 KB SRAM.

OTA updates must be supported.

Must log events with timestamps from RTC.


Secondary MCU (STM32/ATmega/Nuvoton):

Hardware UART with multiple baud rate support.

Hardware timers for PWM capture.

ADC channels for DC-shift level sensing.

Watchdog enabled for stability.


Firmware Requirement:

Written in C/C++ (Arduino IDE/ESP-IDF for ESP32, Keil/STM32Cube or AVR-GCC for co-MCU).

Must be modular and well-documented for future updates.




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5. Signal Capture and Translation (Deep Detail)

UART: Support variable parity, stop bits, idle detection.

PWM: Detect and regenerate accurate duty cycles.

DC Shift: Detect high/low logic, voltage range 0–15 V.

Auto-learn must capture unknown protocol timing and save as temporary profile.

Translator logic must support bidirectional handshaking (commands + ACK).



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6. Display and UI

LCD should display:

Indoor frequency.

Outdoor frequency.

Baud rate.

Duty cycle %.

Power source.

Error messages.

Warranty status.


Menus accessible via push buttons:

Mode Select.

Logs.

Settings.

Service Mode (hidden combo).




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7. Memory Management

EEPROM must store:

Last 10 configurations.

Last 10 fault logs.

Warranty expiry timestamp.


Memory wear-leveling must be implemented to avoid corruption.



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8. Security (More Detail)

First boot requires PIN entry (randomly generated).

PIN visible for only 20s.

After pairing with one indoor-outdoor set, brand lock is enabled.

Firmware must be locked against tampering (secure boot or firmware encryption on ESP32).

App lock prevents unauthorized ON.



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9. Mobile App Requirements

Must connect via Wi-Fi or BLE.

Functions:

ON/OFF.

Mode switch (translator/simulator/learn).

Fault log view.

Live diagnostics (baud, frequency, duty).

OTA firmware update.


App should be simple, bilingual (English + Hindi option).

Optional: QR code links directly to app download page.



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10. Testing & Quality Control (More Detailed)

Unit must pass:

Power cycle test (100 cycles).

Signal test (connect indoor of brand A, outdoor of brand B).

Surge test (input 270 V AC for 5s).

Reverse polarity test on DC input.

Fault injection test (missing signal).


QC Checklist must be documented and delivered.



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11. Packaging Requirements

Box must include:

Device.

AC cable.

DC cable.

Quick Guide.

Warranty Card.

Sticker with QR code.


Box should be professional, with brand: “Sagar Refrigeration Tools – USG7007”.



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12. Expansion and Future-Proofing

Extra UART/I²C pins on header.

Future support for cloud logging.

Future AI waveform analysis: device suggests most likely brand based on captured data.



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13. Documentation Deliverables

1. Schematic + PCB (EasyEDA/Altium).


2. Gerbers + Drill files.


3. BOM with MPN + LCSC codes.


4. Firmware source (ESP32 + STM32/Atmega).


5. Mobile App APK + Source.


6. Wiring Diagram.


7. USB Update Guide.


8. QC Test Checklist.


9. Quick Install Guide.


10. Warranty Card + Serial system.


11. Final Master PDF (all sections merged).


12. Enclosure Drawing + Panel Cutouts.




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14. Branding

Splash: “Sagar Refrigeration Tools – USG7007”.

LCD: Shows contact numbers +91 7007940949 / +91 9598360280.

PCB Silk: Only +91 9598360280.



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15. Supported Brands

Voltas, Daikin, LG, Whirlpool, IFB, Toshiba, Marq, Cruise, Panasonic, Haier, Lloyd, Godrej, Blue Star, Mitashi, Carrier, Hitachi, Samsung, O General, Midea/Gree.


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Final Summary

USG7007 must be a production-ready, professional-grade tool covering:

Hardware: PCB, SMPS, isolation, protections.

Firmware: ESP32 + Secondary MCU, profiles, logs, security.

Software: Mobile app (Wi-Fi/BLE, OTA).

Safety: Surge, EMI, ESD, HV mis-wire protection.

Testing: Self-test, QC checklist, factory validation.

Documentation: Complete package for manufacturing, end-users, and warranty." (client-provided description)