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An ECE student
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An ECE student
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MohansaiPotnuru/README.md

Hi, I'm Mohan Sai 👋

Embedded Systems · RTOS · IoT · VLSI / ASIC Physical Design
I take ideas from the transistor to the cloud: register-level firmware, real-time scheduling, connected devices and RISC-V silicon.
Everything I ship comes with tests, CI and documentation.

Portfolio LinkedIn Kaumodaki NexusGrid IETE Student Forum Chairperson Location

🧑‍💻 About me

  • 🔌 Embedded Systems & IoT Engineer at Kaumodaki NexusGrid: ESP32 / ESP32-CAM devices, sensor networks, gas and air-quality analog front-ends (KiCad), 4G LTE + GPS trackers, BLE load cells and health-monitoring hardware
  • 🎓 B.Tech ECE at Dr. Lankapalli Bullayya College of Engineering (2027), after a Diploma in ECE (82%) and a 6-month industrial training at CEMS with 50+ embedded and IoT prototypes
  • 🧠 I like owning the whole stack: datasheet → registers → drivers → RTOS tasks → protocols → dashboard → silicon
  • 🧪 Engineering bar: deterministic timing, tested pure logic, sanitizer-clean C, reproducible builds and signoff-clean layouts
  • 🎯 Open to embedded firmware, RTOS, IoT and VLSI / physical-design roles

🧭 Engineering depth across ECE

Domain What I actually do Proof
Bare-metal firmware Cortex-M4 register-level drivers, timer input capture for µs edge timing, ISR→main deferred work, CRC-protected wear-levelled flash config IRSense
RTOS & real-time FreeRTOS task-set design with rate-monotonic priorities, response-time analysis, ISR→task deferral via stream buffers and event groups, mutexes with priority inheritance, zero-heap static allocation, watchdog supervision rtos-condition-monitor, RTOS internship (CSC India / APSCHE)
IoT & connectivity ESP32 Wi-Fi + MQTT with echo-loop-safe topic design, web dashboards, RFID, energy metering, BLE, 4G LTE / GPS SmartHomeAutomation, DRE-MachGuard
Digital design & VLSI Verilog SoC integration (PicoRV32, boot ROM, MMIO UART), self-checking testbenches, synthesis, floorplan, CTS, routing, multi-corner STA, DRC / LVS / antenna signoff RISC-V SoC on SKY130
Embedded Linux Yocto-based SAMA5D2 board bring-up with libmraa: GPIO, ADC, PWM, SPI, Wi-Fi MRAA RuggedBoard
Hardware & sensors Sensor interfacing and conditioning (NPTEL Sensors & Actuators, Elite), KiCad PCB design, power and battery systems, EV charging and BMS Solar EV charging station, EV workshop
Data & ML at the edge Leakage-free scikit-learn pipelines, model comparison, feature engineering on sensor time series AQI Prediction

🚀 Featured projects

⏱️ rtos-condition-monitor: FreeRTOS on STM32F401

Condition-monitoring node with 5 analysed tasks (exact response-time analysis at boot, using budgeted or measured WCETs), zero heap, a supervisor that feeds the IWDG only while every task is alive, fault records that survive reset with fault injection, and COBS/CRC telemetry. CI runs ASan/UBSan unit tests, cppcheck and a QEMU boot test of the firmware on every push.

FreeRTOS V11 C Cortex-M4F RTA QEMU CI 24k+ test checks

📟 IRSense: IR counter & conveyor monitor

Bare-metal STM32F401 firmware that turns an IR sensor into a measurement instrument: µs edge timing, jam/rate/intrusion alarms, serial CLI and wear-levelled, CRC-protected flash config.

C STM32 Cortex-M4 45 unit tests ASan/UBSan CI v1.0.0 release

🧬 RISC-V UART SoC on SKY130

32-bit PicoRV32 SoC with boot ROM and memory-mapped UART, hardened RTL → GDSII with LibreLane on the SkyWater 130 nm PDK. Warning-free signoff across 9 PVT/RC corners: DRC, LVS, antenna, slew, cap and fanout all clean.

Verilog RISC-V LibreLane OpenROAD 9-corner STA GDS release

🏠 ESP32 Smart Home Automation

Modular home-automation firmware: environment and gas/smoke safety sensing, RFID door access, PZEM-004T energy metering, MQTT, web dashboard and OLED, with manual override.

C++ ESP32 MQTT arduino-cli CI (2 cores)

🛠️ DRE-MachGuard: offline machinery fault monitor

ESP32 condition monitor for remote sites with no internet: DS18B20 temperature, supply voltage, current and vibration events, rule-based diagnostics, OLED and 3-colour alerts. Top 6 finalist with prize, DRE Enterprise Hackathon '26.

ESP32 DS18B20 condition monitoring offline-first

🌫️ AQI Prediction (AICTE × Shell)

Daily Air Quality Index prediction for 26 Indian cities with leakage-free scikit-learn pipelines. 5 models compared, Random Forest R² 0.91. Top 40 project nationally.

Python scikit-learn pandas Jupyter

🐧 MRAA on RuggedBoard-A5D2X

GPIO / ADC / PWM / SPI / Wi-Fi guides and Python examples for an industrial Microchip SAMA5D2 Yocto Linux board.

Embedded Linux Yocto libmraa

📚 100 Advanced C & Python Programs

Self-testing programs on bit manipulation, pointers, memory layout, function pointers, metaprogramming and concurrency, checked with GCC/Clang sanitizers and Python 3.10–3.13 in CI.

C Python embedded C interview prep

📐 How I build firmware

 Requirements → timing budget → state machines → pure, host-tested logic → thin HAL/BSP → on-target test → CI → release
  • Determinism first: every ISR is short, every loop has a bounded worst case, and every task has a period and a deadline
  • Split pure from hardware: CRC, filters, parsers and state machines compile on the host and run under ASan/UBSan
  • Fail loudly, recover safely: watchdogs, CRC-checked config, defaults on corruption, alarms with hysteresis
  • Signoff mindset from VLSI: no "it works on my board"; numbers, corners and reports or it didn't happen

🏆 Achievements & leadership
🥇 Top 6 Finalist + prize, DRE Enterprise Hackathon '26 (Team INVENTORS, DRE-MachGuard) Oct 2026
🏅 Top 40 project nationally, AICTE × Shell India Skills4Future (AI & Data Analytics) 2025
🛰️ Lead Support, NASA International Space Apps Challenge, Visakhapatnam 2025 & 2026
📡 Chairperson, IETE Student Forum, DLBCE current
⚡ Resource Person, 3-day EV Technology workshop (DIET × APSSDC): batteries, BMS, motors, charging 2026
🇮🇳 Stage II qualifier, Viksit Bharat Young Leaders Dialogue 2026 2026
🎪 Main Student Coordinator, Technotsav (ECE) · represented Kaumodaki NexusGrid at IoT Summit '26 and Future Skills Summit 2026 2026
🔋 Team Lead, solar-powered EV charging station (Diploma final-year project) 2023

📜 Certifications & training

  • NPTEL Sensors and Actuators (Elite, 12 weeks) · Cisco Introduction to IoT · Introduction to IoT and Digital Transformation
  • RTOS internship (CSC India / APSCHE, 2 months) · Full Stack Python & Agentic AI internship (CSC India / APSCHE)
  • CII Applied Machine Learning & AI (INDIAai) · CII DX-EDGE Digital Maturity Diagnostic Framework (NITI Aayog / AICTE)
  • MongoDB Basics for Students · Automation Anywhere Essentials · Salesforce Agentblazer Champion · Agnirva Space & AI internships (AICTE recognised)
  • 30+ certifications in total, from Cisco, NIELIT, ISRO, TCS iON, Coursera and Great Learning

🧰 Tech stack

Languages
C C++ Python Verilog ARM Assembly

MCUs, SoCs & boards
STM32 ESP32 Arduino and NodeMCU Raspberry Pi Microchip SAMA5D2 RISC-V

Real-time, embedded & protocols
RTOS and FreeRTOS Yocto Linux MQTT BLE and Wi-Fi 4G LTE and GPS UART SPI I2C 1-Wire

EDA & VLSI
LibreLane and OpenLane Yosys and OpenROAD Magic, KLayout and Netgen Icarus Verilog SKY130 PDK KiCad

Tools & workflow
STM32CubeIDE PlatformIO Git GitHub Actions scikit-learn Jupyter

🔭 Currently working on

  • ⏱️ Validating rtos-condition-monitor on the NUCLEO board: measured WCETs vs. budgets, watchdog and fault-recovery tests
  • 🧬 Next SoC revision: SPI/GPIO peripherals, a Wishbone bus and gate-level simulation against the signed-off netlist
  • 📶 Low-power IoT nodes: sleep-mode budgets, battery-life estimation and OTA-safe update layouts

🐍 Contribution activity

Contribution snake animation

🌐 Portfolio · 📫 reach me on LinkedIn · browse all repositories

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  1. IRSense-NUCLEO-F401RE IRSense-NUCLEO-F401RE Public

    IR object counter & conveyor monitor firmware for STM32 NUCLEO-F401RE: µs edge timing, alarms, CLI, flash config, unit tests, CI

    C

  2. riscv-uart-sky130-soc riscv-uart-sky130-soc Public

    32-bit RISC-V SoC (PicoRV32 + boot ROM + memory-mapped UART) hardened RTL-to-GDSII on SkyWater SKY130 with LibreLane. Warning-free signoff across 9 corners. Self-checking testbench + CI.

    Verilog

  3. Air-Quality-Prediction-by-AICTE Air-Quality-Prediction-by-AICTE Public

    AQI prediction for 26 Indian cities (2015-2020) with scikit-learn: leakage-free pipelines, 5 models compared, Random Forest R² 0.91. AICTE Cycle-4 internship project.

    Jupyter Notebook 1

  4. MRAA---RuggedBoard---A5D2X MRAA---RuggedBoard---A5D2X Public

    Python MRAA examples and guides (GPIO, ADC, PWM, SPI, Wi-Fi) for the RuggedBoard-A5D2X (Microchip SAMA5D2, Yocto Linux)

  5. SmartHomeAutomation SmartHomeAutomation Public

    Modular ESP32 smart-home firmware: BME280/BH1750/MQ-2/MQ-5/PIR sensing, RFID door access, PZEM-004T energy metering, MQTT, web dashboard, OLED and manual override

    C++

  6. rtos-condition-monitor rtos-condition-monitor Public

    FreeRTOS condition-monitoring node for STM32F401 (NUCLEO): analysed task set (RTA), zero heap, supervised IWDG, persistent fault records, COBS/CRC telemetry, QEMU boot test in CI

    C