Firefighter Exoskeleton — Battery Level Indicator
A small face for a 24-volt system.
This is a battery level indicator for a firefighter exoskeleton: a custom PCB that reports how much charge is left in the pack.
It is for the firefighters wearing the suit, who need to read the battery state without stopping to open anything up.
My team and I designed and tested the board. It runs off the exoskeleton’s 24 V power system, with voltage regulation down to logic levels and an OLED for the readout. I selected the regulation and protection parts, and we verified the populated prototype against a bench supply and the real pack.
The hard part was not the layout but the calibration — characterizing the pack’s voltage curve under load so the number on the screen means the same thing whether the suit is idle or moving.
