MADHAVAKUMAR K S

Worked on wireless charging systems at the Centre of E-Mobility (CEM) Lab, developing and implementing Model Predictive Control (MPC) algorithms to optimize charging performance, efficiency, and system stability.

Design and Fabrication of Solar Panel Cleaner (Automation & IoT) 

• Designed the mechanical frame and motorized rotating brush assembly for an automated solar panel cleaning system, sized to traverse standard panel dimensions without surface damage. 

• Developed an Arduino-based control system with motor drivers for brush rotation and linear traverse motion, controlled via a Bluetooth-enabled mobile application for remote operation.

Design and Fabrication of Electric Stair Climbing Trolley (Mechanical & Vehicle Component Design) 

• Designed the mechanical structure and tri-star (tri-wheel) climbing mechanism in CAD, enabling stable ascent and descent of standard staircases while carrying transport loads. 

• Selected and sized the DC gear motor, drivetrain, and battery pack based on torque and power calculations derived from required load capacity and stair geometry (riser height and tread depth). 

• Developed a motor control circuit with speed regulation and direction control to ensure smooth.

Development of Digital Twin of a BDC Electric Motor for Monitoring Motor Performance 

• Designed and implemented a Secure Digital Twin Framework for a 24V, 350W BDC electric motor, integrating real-time sensor data acquisition, a physics-based MATLAB/Simulink Digital Twin, an edge-deployed Intrusion Detection System (IDS), encrypted MQTT/TLS communication, and a cloud-hosted Firebase dashboard with automatic motor control. 

• Built a multi-physics Digital Twin in MATLAB/Simulink (electrical, mechanical, thermal, and NVH sub-models) synchronized in real time with live sensor data from a Raspberry Pi 4B. 

• Designed and validated an 8-rule Host Intrusion Detection System (HIDS) in Python, detecting sensor spoofing, replay, data injection, and other attacks within 50 ms. 

• Implemented MQTT over TLS 1.3 with a 3-certificate PKI for mutual authentication and AES-256-GCM encrypted sensor-to-cloud communication. 

• Developed a live Firebase web dashboard (HTML5/JavaScript) with real-time charts, fault-alert lamps, IDS alert logging, and automatic closed-loop motor control. 

• Achieved Digital Twin thermal accuracy of RMSE < 0.4°C; design aligned with ISO 26262 (ASIL D), ISO/SAE 21434 (CAL 4), AUTOSAR, and UNECE WP.29 / UN R155 standards. Development of LKA with Surface Monitoring in Concept Car (Vehicle Systems Design & Embedded Control) 

• Designed and implemented a Lane Keep Assist (LKA) system on a CATIA-modelled RC concept car platform, integrating a Raspberry Pi 4B and Pi Camera module for real-time lane detection using OpenCV-based image processing (edge detection, Hough transform, and perspective warping). 

• Developed a closed-loop PID control algorithm for adaptive steering and throttle modulation, dynamically adjusting correction gains based on detected lane curvature and lateral deviation. 

• Integrated surface condition monitoring via onboard IR/ultrasonic sensors to classify road surface type (dry, wet, gravel) and adapt control gains for stable lane-keeping across varying traction conditions.