Hardware and firmware engineer

Abhay builds embedded firmware, high-voltage boards, CAN networks, race cars and much more

I work across embedded firmware, board design and battery systems. I designed I-Align, a wearable for post-retinal-surgery patients, and a GRU-based CAN intrusion detector that runs in real time on an ESP32 and is moving to an STM32H7 with far more functionality. In batteries and EVs I’ve worked on BMS hardware and firmware, high-voltage electronics and cell modelling. As team captain and powertrain engineer of Ojas Racing I led 30+ engineers while staying hands-on with the electronics.

I’m interested in working on automotive electronics, EVs and autonomous vehicles.

Projects

7 projects
  • Custom BMS monitoring board wired to three pouch cells on a test bench

    Battery management system

    600 V

    Ojas Racing, 2024–2026

    Custom BMS for a 3P140S Formula Student accumulator. STM32H7 master with LTC6804 cell monitors over isoSPI, DMA-based voltage acquisition, CAN telemetry, cell balancing, fault detection and SoC estimation. I did the schematics, multi-layer PCBs, firmware and bring-up.

    STM32H7LTC6804isoSPICANAltium
  • Bare high voltage fault detection board with high-voltage and low-voltage halves separated by an isolation slot

    High voltage fault detection board

    HV

    Ojas Racing

    A high-voltage board for the Ojas car with isolated high-voltage and low-voltage sides, built to detect faults.

    High voltageIsolationPCB design
  • Assembled I-Align v2.0 board with ESP32-C3 module and USB-C connector

    I-Align v2.0

    35 × 45 mm

    Accepted for panel discussion, VRSI National Conference

    A wearable that tracks orientation for patients recovering from retinal surgery. Compact board with an ESP32-C3, MPU6050 and EEPROM; Kalman-filter orientation tracking, on-board logging and deep-sleep power saving.

    ESP32-C3MPU6050Kalman filterKiCad
  • accuracy %target10090050100 mslatency on ESP32GRU 99.11D-CNN 97.1threshold 91.3

    CAN bus intrusion detection

    67 ms

    Paper accepted at iSENSE, IIIT Kottayam

    A GRU-based intrusion detector that runs on the microcontroller itself. Two ESP32 nodes sit on a 500 kbps CAN bus: one captures frames in listen-only mode, the other runs a 16-unit GRU (TFLite Micro) over 20-frame windows. It classifies DoS, fuzzing and spoofing traffic with 99.1% accuracy and 67 ms end-to-end latency, in 82 KB of flash and 29 KB of RAM, ahead of 1D-CNN and threshold baselines. It is moving to an STM32H7 next, with far more functionality.

    ESP32TWAI / CANFreeRTOSTFLite MicroPython
  • MATLAB plots: EKF-estimated state of charge tracking the measured state of charge from 90% down to 0% over about 22,000 seconds, and the estimation error settling close to zero after the first few minutes

    EKF state-of-charge estimator

    <2% error

    SMART Lab, IIT Madras, 2025–2026

    An extended Kalman filter in MATLAB that estimates a lithium-ion cell’s state of charge, validated against lab charge–discharge cycles with under 2% error.

    MATLABEKFBattery testing
  • R0R1 C1R2 C2OCV

    LFP degradation and equivalent-circuit model

    2RC

    UD Trucks, 2026

    A physics-informed model of LFP capacity fade and resistance growth, coupled to a 2RC equivalent circuit parameterised over temperature, SoC, cycle count and age for SoH estimation.

    MATLABSimulinkPyBaMMECM
  • test MAE, mmHgiCare as-isLinear+CCTRand. forestXGBoost3.213.002.922.90lower is better

    Icare-ML

    2.90 mmHg

    GitHub

    Predicts Goldmann applanation tonometry (GAT) eye pressure from central corneal thickness and iCare tonometer readings, trained on about 6,600 clinical eye records. A tuned XGBoost model brings the test error to 2.90 mmHg MAE (R² 0.73), down from 3.21 mmHg when the iCare reading is taken as-is.

    PythonXGBoostscikit-learnRegression
    View on GitHub

Experience

May 2024 – Nov 2026
Team captain and powertrain engineerOjas Racing

Designed the BMS and high-voltage boards for the 600 V Formula Student EV; led 30+ engineers.

May 2026 – July 2026
xEV internUD Trucks

LFP degradation model and 2RC equivalent circuit model for SoH estimation.

May 2025 – Jan 2026
Research internSMART Lab, IIT Madras

EKF state-of-charge estimator under 2% error; BMS testbench support.

Education

2023 – 2027
B.Tech, Electronics and Communication EngineeringVIT Vellore

Skills

Firmware

Languages and OS
Embedded C/C++PythonFreeRTOSBare-metalLinux
Platforms
STM32 (Cortex-M)ESP32
Interfaces
CAN / FDCANisoSPISPII2CUARTDMAInterrupts

Hardware

Design
Altium DesignerKiCadSchematic captureComponent selectionMulti-layer PCB layout
Bring-up and test
OscilloscopesLogic analysersDebuggingDFM
High voltage
600 V systemsIsolationDGUV 209-093 Level 3E

Battery and EV

Systems
BMS designCell balancingSoC / SoH estimation
Modelling
Extended Kalman filterEquivalent circuit modelsDegradation modellingSPM / DFN
Tools
MATLABSimulinkSimscapePyBaMM
Publications
  • Real-Time CAN Bus Intrusion Detection on Edge Microcontrollers Using a Lightweight GRU Neural Network, accepted at iSENSE, IIIT Kottayam.
  • I-Align, accepted for panel discussion at the VRSI National Conference.