Customer Background & Requirements

The customer required a high-performance Cathodic Protection (CP) Controller capable of maintaining optimal protection levels for metallic structures such as pipelines and storage tanks. The system needed to operate at 24 V and up to 25 A, with the ability to dynamically control output voltage and current based on feedback parameters to prevent corrosion effectively. Additionally, the device had to support data logging, real-time monitoring, and alert/alarm management for abnormal operating conditions.

Solution Provided by Electrobit Technology:

Electrobit Technology designed and delivered a smart Cathodic Protection Controller that continuously monitors and regulates the protection potential using feedback-based control algorithms. The system automatically adjusts the output voltage and current according to environmental and system variations to maintain the desired protection potential. It features integrated data logging, fault and alarm management, and remote communication support for comprehensive monitoring and maintenance.

Services Provided:

The project included hardware development, firmware design, and system integration tailored for long-term, reliable field operation in industrial and outdoor environments.

Firmware Development

  • Implemented closed-loop voltage/current control algorithm for precise potential regulation.
  • Developed real-time monitoring and data logging for voltage, current, and potential feedback.
  • Integrated alert and alarm handling for overvoltage, overcurrent, and system fault conditions.
  • Added RS485 communication (Modbus) for remote configuration and monitoring.
  • Designed scheduled data logging system with timestamped records stored in SD card memory. Included watchdog and fault recovery logic for robust, unattended operation.

Hardware Design & Improvement

  • Designed 24 V, 25 A power control stage with high-efficiency switching components.
  • Integrated high-accuracy analog sensing for voltage, current, and potential feedback channels.
  • Added galvanic isolation and surge protection for field reliability.
  • Included LCD display and user interface for configuration and status indication.
  • Implemented comprehensive alarm indication through buzzer and LED signals.
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Challenges Overcome:

Maintaining stable output control under variable environmental and load conditions. Ensuring accurate feedback measurement for corrosion protection potential. Managing data logging and alarm systems without affecting real-time control performance.

 

Technologies Used:

  • PWM-Based Power Control (24 V, 25 A)
  • Closed-Loop Voltage and Current Regulation
  • Analog Feedback Measurement
  • RS485 (Modbus) Communication
  • SD Card Data Logging (FAT32)
  • Real-Time Clock for Timestamped Logs
  • Industrial Power Supply and Surge Protection

Industry Tagline :

Cathodic Protection | Corrosion Prevention | Power Control | Data Logging | RS485 Communication | Industrial Automation