Contact person: Project: Universal AC Communication Translator (USG7007)

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Location: Indore, India

Budget: Recommended by industry experts

Time to start: As soon as possible

Project description:
"Project: Universal AC Communication Translator (USG7007)

1. Objective

The device (USG7007) is designed to connect, translate, and simulate communication between indoor and outdoor PCBs of inverter air conditioners from different brands.

Normally, indoor and outdoor boards of different brands cannot communicate, because each brand uses its own protocol (UART, PWM, DC shift, etc.).

The USG7007 will sit in the middle and act as a translator + simulator + diagnostic tool.



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2. Budget Optimization

To reduce project cost while keeping reliability:

Use ESP32 (dual core, Wi-Fi/Bluetooth, plenty of GPIOs) instead of expensive MCU boards.

Select off-the-shelf SMPS module for AC-to-DC power.

Use 16x2 LCD with I2C instead of larger TFT (lower cost, easy to control).

Keep PCB size around 10 cm × 6 cm (optimized for JLCPCB).

Bulk component sourcing (resistors, capacitors, connectors) reduces per-unit price.



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3. How Communication Works

Step 1: Device receives signal from indoor PCB.

Step 2: It decodes this signal into a digital format.

Step 3: Device maps/rewrites the decoded signal into the target outdoor brand’s language.

Step 4: Outdoor’s response signal is captured, decoded, and translated back for the indoor unit.


This way, two different brands can “talk” to each other.
If one side is missing (indoor only or outdoor only), the device can simulate the missing partner using its signal database.


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4. Application Role

A mobile app (via Wi-Fi or Bluetooth) will allow:

Brand selection (Voltas → LG, Daikin → Panasonic, etc.).

Turning ON/OFF the device.

Viewing live data (frequency, voltage, signal type).

Firmware update via OTA.


If the device is locked by PIN (first installation), app is used to activate/unlock.

Warranty details also stored in app (based on internal RTC).



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5. Hardware Overview

Core MCU: ESP32-WROOM module.

Power:

AC-DC SMPS module (230V AC → 5V DC).

Optional 5V DC input.


Protection:

Reverse polarity protection.

Over-voltage shutdown (>6V DC).

High-voltage mis-wiring protection.


Memory: EEPROM/Flash for storing last working config + logs.

RTC: For warranty tracking.

Display: 16x2 I2C LCD, showing menus, errors, brand selection.

Buttons: Push buttons for menu navigation and manual control.

Buzzer: For alerts and warnings.

USB-C Port (CH340/CP2102): For firmware updates/debugging.



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6. Software / Firmware Overview

Signal Handling Module:

Captures signal waveforms from indoor/outdoor.

Converts them into protocol-specific data.


Translation Engine:

Maps one brand’s signal into another’s compatible format.

Supports multiple modes: Manual, Auto-Learn, Simulation.


Security Module:

PIN lock on first installation.

Device locks to first indoor/outdoor pair.


Diagnostics Module:

Self-test on startup.

Logs last errors into EEPROM.

Displays “Indoor not sending” / “Outdoor not sending.”


Mobile API: BLE/Wi-Fi hooks for app communication.



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7. Display Information

The 16x2 LCD will show:

Current operating brand mode (e.g., Voltas → LG).

Signal status (Indoor OK / Outdoor OK / Error).

Real-time frequency & voltage of signals.

Warranty info (e.g., Warranty Expired after 1 year).

Power source (AC mains or 5V DC).

Last fault log (for technicians).

Contact details:

Sagar Refrigeration
Sagar: +91 7007940949
Vijay: +91 9598360280



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8. Warranty System

Device has an internal RTC (Real-Time Clock).

From the first power-on, it starts counting 1 year.

After expiry, the display shows: “
Warranty Expired – Contact Service.”



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9. Handling Different Brands

Each brand uses different communication protocols (UART @ specific baud rates, PWM at certain duty cycles, or DC voltage shifts).

The USG7007 will:

Store protocol data patterns in firmware (database).

Auto-detect signal type using waveform analysis.

Translate accordingly in real time.


Example:

Indoor = Daikin, Outdoor = LG.

Device captures Daikin UART signal → converts → outputs LG-style PWM.

Outdoor replies in LG format → converted → sent back in Daikin format.




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10. Guarantee

Hardware protected with surge, reverse polarity, and over-voltage circuits.

Firmware is locked (cannot be copied or modified).

First-use PIN lock ensures device cannot be reused fraudulently.

1-year warranty tracked automatically.



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In summary:

Hardware: ESP32 + SMPS + EEPROM + RTC + LCD + Buttons + USB-C.

Software: Signal translation + AI Auto-learn + Security + Diagnostics.

Application: Remote brand selection, ON/OFF, warranty tracking.

Display: Real-time signal data, brand info, errors, warranty, contact details.

Communication: Works between any indoor/outdoor pair, even if they are different brands.

Our project is similar in concept to a BACnet–Modbus gateway. Just like the gateway sits between two systems, captures the data, decodes it, translates it, and re-encodes it in real time

Pin-based 1st time activation + brand lock.

Profile lock (no overwrite).

Signed prof. packages (opt.)

Audit log in app (who changed what)
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6. Operation Flow

In Lab (dev/test):

1. Select brand-A indoor (fake box) + brand-B outdoor (fake box).


2. Connect USG7007 betwen them.


3. Run scenarios (cool, heat, temp step , errors).


4. Save profle in Eeprom.


In Field:

1. Plug betwen real indoor & outdor.


2. Translator auto detect / use saved profile.


3. Translate every frame both ways safely.

7. Deliverables

1. USG7007 main hardware (Gerber + PCB + BOM + firmware).


2. Fake indoor sim. box.


3. Fake outdoor sim. box.

4. Sensor / press / UVW emulator kit.

5. Firmware v1.0 (rules + fsm + ml assist).


6. Pc / Mobile softwre.


7. Starter profiles (Top 10–12 brands).


8. Test scripts (bench).

9. Complete docs (wiring, user guide , service , warranty).

8. Limitations

some rare brand handshakes may need real field test.

UVW load not 100% simulated (only signal f/b).

not fully universal in 1 shot, lib can grow.

9. Advantages

No need of real indoor/outdor during dev.

Faster dev cycle, safe bench testing.

Plug-and-run in field.

Easy future expan (profiles share among enggs).
Please note: For my project, I need the complete solution including hardware, software, and mobile application. All three parts must be developed together as a full package." (client-provided description)