Multi-Protocol Data Logger Kit

Industrial data logger supporting RS485, RS232, GPRS, and Wi-Fi with 16 digital inputs, 16 analog inputs, backup battery, and smart charger — designed in Altium Designer

Project Overview

Designed a complete industrial data logger kit providing a unified solution for multi-protocol communication and data acquisition. The kit integrates RS485, RS232, GPRS, and Wi-Fi connectivity alongside 16 digital inputs, 16 analog inputs, onboard MicroSD logging, backup battery with smart charging, and comprehensive protection circuits — all designed in Altium Designer.

Altium Designer 3D render showing the full board layout — Wi-Fi module, MCU, relay, GPRS module, RS232 DB9 connector, 16-channel digital inputs bank, and all screw terminal I/O connections.
Assembled data logger kit showing the GPRS A6 module, ESP8266 Wi-Fi module, relay outputs, MCU, RS232 DB9 connector, MicroSD adapter, backup power section, and 16-channel screw terminal banks for digital and analog I/O.

Key Features

Communication Protocols

  • RS485 — industrial serial communication via screw terminal interface
  • RS232 — standard serial via DB9 connector
  • GPRS — cellular data transmission for remote monitoring
  • Wi-Fi — wireless local connectivity via ESP8266 module

I/O Capabilities

  • 16 Digital Inputs — screw terminal bank for discrete signal acquisition
  • 16 Analog Inputs — screw terminal bank for sensor and signal monitoring
  • MicroSD Card — onboard data logging and local storage

Power System

  • Backup Battery — ensures continuous operation during power outages
  • Smart Battery Charger — intelligent charging with battery level indication LEDs

Protection

  • Short Circuit Protection — safeguards all output and input channels
  • Reverse Polarity Protection — prevents damage from incorrect wiring
  • ESD Protection — on all external-facing interfaces

Hardware Architecture

Block Implementation
Main MCU QFP microcontroller — I/O control, protocol handling, logging
Wi-Fi ESP8266 module — wireless data transmission
Cellular GPRS module — remote data upload
Serial RS232 via DB9, RS485 via screw terminals
Storage MicroSD card adapter for local data logging
Digital I/O 16-channel screw terminal bank
Analog I/O 16-channel screw terminal bank
Power backup Battery + smart charger with level indicators

Technologies & Tools

  • Altium Designer — full schematic capture and PCB layout
  • Embedded C — firmware for data acquisition and multi-protocol communication
  • RS485 / RS232 / GPRS / Wi-Fi protocol implementation
  • Industrial protection design (ESD, reverse polarity, short circuit)

Key Achievements

✅ Unified multi-protocol platform (RS485, RS232, GPRS, Wi-Fi) on a single board
✅ 16 digital + 16 analog inputs for comprehensive industrial data acquisition
✅ Onboard MicroSD logging for offline and standalone operation
✅ Smart battery charger with level indication for reliable backup power
✅ Full protection suite — ESD, reverse polarity, and short circuit
✅ Designed entirely in Altium Designer