Projects NetSure MiniUPS Pro
Active Development · CircuitLabs 2026

NETSURE
MINIUPS
PRO.

An intelligent inline router backup power system engineered to keep your internet alive through every power cut — automatically, silently, and without interruption.

≤15ms
Failover switch time
3.6 Ah
Battery capacity
ESP32
Smart MCU control
Real‑Time
OLED monitoring
Never Go Offline Again
Auto Failover
ESP32 Smart Control
OLED Monitoring
Inline Router UPS
Power Electronics
IoT Development
Active Development
Never Go Offline Again
Auto Failover
ESP32 Smart Control
OLED Monitoring
Inline Router UPS
Power Electronics
IoT Development
Active Development
The Problem

Power cuts shouldn't mean
internet cuts.

In India and across developing markets, power outages are a daily reality. Your router dies the instant electricity fails — snapping your smart home, work calls, and connected devices offline in an instant. Existing UPS solutions are either massive, overpriced, or built for desktop computers — not the humble router sitting in the corner.

Abrupt Internet Loss

A power cut kills your router instantly — mid-call, mid-upload, mid-game. No warning, no graceful handoff. Just silence.

💼

Remote Work Disruption

Video calls crash. Deadlines slip. Clients wait. For remote professionals, a router outage is a productivity catastrophe.

🏠

Smart Home Paralysis

Smart lights, security cameras, door locks — all of them depend on a live network. When the router dies, the entire system goes dark.

🗃️

Bulky "Dumb" UPS Systems

Standard UPS units are oversized, power-inefficient, noisy, and completely unaware of what they're protecting. No monitoring, no intelligence.

Reliability Score — Existing Solutions
Standard Wall Socket (No UPS)
Zero protection. Router dies the moment power fails.
Generic Desktop UPS (Overkill)
Works, but bulky, inefficient, zero monitoring, and expensive.
NetSure MiniUPS Pro
Purpose-built, intelligent, compact, fully monitored.
The NetSure Difference

Designed from the ground up for a single purpose — keeping routers alive. Compact enough to mount on a wall, smart enough to know exactly what's happening inside.

The Solution

Meet NetSure MiniUPS Pro.

NetSure MiniUPS Pro is an intelligent inline backup power system built specifically for routers and small networking hardware. It sits between your wall socket and router — invisible during normal operation, and instantaneous when power fails.

Unlike generic UPS units, NetSure is fully aware of what it's doing. It monitors battery health in real time, manages charging intelligently, estimates remaining runtime, and communicates everything through a crisp OLED display.

The heart of the system is an ESP32 microcontroller — a capable, WiFi-ready embedded chip that handles power switching logic, sensor telemetry, display output, and future connectivity features all in one compact package.

This is not a stripped-down gadget. It's a properly engineered product designed with reliability, usability, and extensibility at its core — built by students, for real-world deployment.

Core Capabilities

Intelligent. Compact.
Always ready.

NetSure MiniUPS Pro detects power failure in milliseconds and switches to battery seamlessly — no reboots, no dropped packets, no disruption. When mains power returns, it switches back and resumes charging, all without any user intervention.

Embedded Systems ESP32 IoT Power Electronics OLED Display Li-Ion Battery
Technical Specs
MCU: ESP32 (Dual-Core 240MHz)
Battery: 3.6 Ah Li-Ion Cell
Output: 5V / 9V / 12V
Failover: ≤15ms switching
Display: 0.96″ OLED (128×64)
WiFi: 802.11 b/g/n (future)
Status: Active Development
Features

What it does.

Auto Failover

Detects power loss and switches to battery in under 15 milliseconds — faster than your router can even register a blip. Zero packet loss, zero reconnection required.

Core Feature
📟

OLED Live Monitor

A crisp 0.96″ OLED display shows battery percentage, estimated runtime, power mode, voltage, and system status — always visible at a glance.

Real-Time
🔋

Smart Battery Tracking

Continuous voltage and current sensing feeds a runtime estimator that accurately predicts how long backup power will last under current load conditions.

ESP32 Powered
📡

WiFi Monitoring Ready

The ESP32's built-in WiFi opens the door for wireless telemetry, web dashboards, and push alerts — all planned for upcoming firmware releases.

Coming Soon
🧩

Modular Architecture

Power management, sensing, control, and display are cleanly separated into logical subsystems — making it easy to upgrade, swap, or extend individual components.

Extensible
🧠

Intelligent Power Control

Adaptive charging logic prevents overcharge, deep discharge, and thermal stress — extending battery service life far beyond what a simple charger could achieve.

Protection System
System Architecture

How it works.

NetSure is structured around five tightly-integrated subsystems. Each handles a specific responsibility — working together to deliver seamless backup power with full situational awareness.

🔌
Mains Input
AC Wall Power
Smart Switch
Auto Failover
🔋
Battery System
Li-Ion 3.6 Ah
🧠
ESP32 MCU
Control Core
📶
Router Output
5V / 9V / 12V
Key design principle: The smart switch operates independently of the MCU. Even if the ESP32 freezes, power switching continues uninterrupted via dedicated hardware logic — ensuring the router stays online regardless of firmware state.
Subsystem 01
Power Input Stage
Accepts mains AC, rectifies and regulates to charging voltage. Monitors presence/absence of mains supply.
Subsystem 02
Battery Management
Li-Ion charging with overcharge, over-discharge, and thermal protection via dedicated BMS IC.
Subsystem 03
Failover Switching
MOSFET-based switch circuit detects mains drop and routes battery power to output in ≤15ms.
Subsystem 04
ESP32 Control Core
Reads sensors, drives OLED, manages display logic, computes runtime estimates, and handles future WiFi telemetry.

The power path is designed for efficiency and redundancy. Mains power charges the battery and simultaneously powers the router output — with seamless battery takeover on failure.

🔌
AC Input
230V Wall
🔄
AC/DC Stage
Rectifier + Reg
⚙️
BMS + Charger
Smart Charge
🔋
Li-Ion Cell
3.6 Ah
DC/DC Boost
5V / 9V / 12V
📶
Router Output
Load
Dual-path design: During normal operation, mains power feeds the router directly through a regulated path while simultaneously maintaining the battery at full charge. On mains failure, the MOSFET switch instantly routes battery power through the boost converter — maintaining stable output voltage across the full battery discharge curve.

The ESP32 is the intelligence layer — reading sensors, running logic, driving the display, and managing state transitions across the system lifecycle.

Firmware Module 01
Power State Manager
Monitors mains presence via ADC, manages state transitions between MAINS / BATTERY / CHARGING / FAULT modes.
Firmware Module 02
Battery Monitor
Continuously samples voltage and current. Runs coulomb-counting algorithm to estimate SoC and remaining runtime.
Firmware Module 03
OLED Display Driver
Renders battery bar, SoC percentage, runtime estimate, power mode indicator, and uptime counter at 4 Hz.
Firmware Module 04
WiFi Telemetry (Planned)
Will expose live status over HTTP/MQTT for web dashboard, mobile app, and smart home integration.
Firmware Module 05
Alert Engine (Planned)
Will push notifications for low battery, power failure events, and charging completion via configured channels.
Firmware Module 06
Fault Protection
Detects overcurrent, thermal anomalies, and deep discharge — triggering safe shutdown sequences to protect hardware.
Development approach: Firmware is being built module-by-module with hardware simulation first, then validated on physical prototypes. Each module has defined I/O contracts so they can be developed and tested independently.

NetSure's monitoring layer provides complete visibility into system state — from the physical OLED on the device to future remote dashboards.

🌡️
Sensors
V, I, Temp
🧠
ESP32 ADC
12-bit Sampling
📊
State Engine
SoC Calculation
📟
OLED Display
Live Output
📡
WiFi / App
Future
Monitoring design philosophy: Every critical value is readable locally on the OLED without any app or connection required. Remote telemetry is an enhancement, not a dependency — the device is fully functional in standalone mode.
Live System Monitor

What you see
on the device.

// OLED Display Preview — Live Simulation
◈ NetSure MiniUPS Pro
POWER MODE MAINS
BATTERY 72%
SOC ▐
RUNTIME EST ~2.6 hrs
OUTPUT 12.0V ✓
UPTIME 04:22:17
● ONLINE ⚡ CHARGING
Battery SoC
72%
Charging from mains
Estimated Runtime
2.6 hrs
At current router load
Power Mode
MAINS
Failover armed & ready
Failover Speed
≤15ms
Sub-frame switching
Output Voltage
12.0V
Regulated DC output
System Status
NOMINAL
All subsystems healthy
System Log — Latest Events
04:22:17  [INFO]  Mains power nominal. Charging active.
04:20:01  [INFO]  SoC reached 70%. Runtime est. updated.
03:58:44  [WARN]  Mains restored after 3m 22s outage.
03:55:22  [CRIT]  Mains failure. Switched to battery.
00:00:00  [INFO]  System boot. Self-test passed. ✓
Build Progress

Where we are
in the build.

NetSure MiniUPS Pro is currently in active development. The architecture is defined, the PCB layout is underway, and firmware modules are being built and tested on evaluation hardware. Every step is being documented openly.

System Architecture
Fully defined — block diagram, subsystem contracts complete
DONE
Component Selection
ESP32, BMS IC, MOSFET switch, OLED module selected
DONE
PCB Layout Design
Schematic done. PCB routing in progress
IN PROGRESS
Firmware Development
Power state manager and OLED driver active. Battery monitor next.
IN PROGRESS
Prototype Assembly & Testing
Pending PCB fabrication
UPCOMING
Field Deployment
Real-world testing & iteration
UPCOMING
2
Firmware modules operational on eval hardware
≤15ms
Target failover switching time (simulated & verified)
3.6 Ah
Target battery capacity — ~3–4 hours at typical router load
Build Philosophy

We're building this the right way — architecture first, hardware second, firmware third. No shortcuts, no untested assumptions. Every decision is documented and reversible. The goal is a product that works first time, every time.

Roadmap

What comes next.

NetSure is designed to grow. The hardware architecture anticipates future expansion, and the ESP32's onboard WiFi unlocks a whole layer of smart features that will come through firmware updates.

Phase 1
Core hardware — complete offline power backup
Phase 2
WiFi dashboard and mobile push alerts
Phase 3
AI analytics, predictive battery health, cloud sync
Completed

Architecture & Design

Full system architecture defined. Block diagrams, subsystem contracts, component selection, and schematic design completed.

Architecture Schematic Component Selection
In Progress

PCB Design + Core Firmware

PCB layout routing underway. Firmware modules for power state management and OLED display active on evaluation hardware.

PCB Layout Firmware ESP32
Upcoming

Prototype Assembly & Testing

First PCB fabrication run, full assembly, lab testing of failover timing, battery protection, and display accuracy under real load.

Prototype Testing Validation
Future

WiFi Dashboard & Mobile Alerts

Local web dashboard served over WiFi. Push notifications for power failure events, low battery warnings, and charge completion.

WiFi Dashboard Alerts
Future

AI Analytics & Cloud Monitoring

Predictive battery health modelling, anomaly detection, long-term trend analysis, and optional cloud sync for multi-site deployments.

AI Cloud Analytics
Future

Larger Battery Variants & Scalability

Extended capacity variants for higher-load networking gear. Modular battery swap design for easy replacement and capacity upgrades.

Hardware v2 Scalability Modular
Future Vision

Where this goes.

📱

Native Mobile App

A dedicated companion app for iOS and Android. Monitor your router's backup status from anywhere, receive instant alerts, and review power event history — all from your phone.

PLANNED
🤖

AI-Powered Analytics

Machine learning models trained on your battery's discharge patterns to predict failures before they happen, optimise charging schedules, and extend cell longevity through intelligent management.

☁️

Cloud Monitoring

Optional cloud sync for multi-site deployments — ideal for offices, clinics, or any environment running multiple networked locations. One dashboard, complete visibility.

PLANNED
🔔

Smart Alert Engine

Configurable notifications via WhatsApp, Telegram, email, or webhook. Know the instant your power fails — before anyone even notices the internet is down.

🔋

Swappable Battery Packs

Hot-swappable, standardised battery modules that can be upgraded without tools. Scale from 3.6 Ah to 10+ Ah as your needs grow — without replacing the whole unit.

🏠

Smart Home Integration

Native support for Home Assistant, Google Home, and Matter — turning NetSure into a smart home power sensor that can trigger automations, scenes, and alerts on power events.

Active Development · Open Build

FOLLOW THE
BUILD.

We build openly. Every schematic, every firmware commit, every decision — documented on GitHub for anyone to follow, fork, or contribute to.