Microcontroller based programmable load

  • Unique Paper ID: 193410
  • Volume: 12
  • Issue: 10
  • PageNo: 8238-8246
  • Abstract:
  • The growing need for accurate testing of batteries, solar panels, and power supply units in portable and energy storage applications has led to a surge in the development of programmable electronic loads. Traditional testing utilizing static resistor banks lacks the dynamic adaptability required for modern energy profiling. This project presents the comprehensive design, mathematical modeling, and implementation of a microcontroller-based programmable electronic load capable of operating in Constant Current (CC), Constant Resistance (CR), and Constant Power (CP) modes. An ESP32 serves as the core processing unit, regulating the load through a discretized Proportional-Integral (PI) closed-loop feedback mechanism to ensure stable operation amidst fluctuating input voltages. A logic-level power MOSFET (IRLZ44N) acts as the primary controllable load element, driven dynamically using Pulse Width Modulation (PWM) signals. Hall-effect current sensors and isolated voltage dividers provide real-time, high-fidelity feedback to the microcontroller. To ensure robust operational safety, an automated protection suite is embedded, featuring thermal cut-offs via an integrated temperature sensor, over- current protection, and an under-voltage lockout to protect lithium-ion test subjects from over-discharge. Furthermore, the system autonomously integrates discharge currents over time to calculate precise battery capacities (Ah), while supporting se- rial data logging for post-test graphical analysis. The proposed architecture is validated via Proteus simulation and physical hardware prototyping, proving to be a highly cost-effective, precise, and reliable instrument suitable for academic laboratories, rapid prototyping, and advanced battery performance evaluations.

Copyright & License

Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

BibTeX

@article{193410,
        author = {AHAMMAD AFSAL and Fasal Muhammad A K and Vishnu K and Elizabeth paul},
        title = {Microcontroller based programmable load},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {12},
        number = {10},
        pages = {8238-8246},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=193410},
        abstract = {The growing need for accurate testing of batteries, solar panels, and power supply units in portable and energy storage applications has led to a surge in the development of programmable electronic loads. Traditional testing utilizing static resistor banks lacks the dynamic adaptability required for modern energy profiling. This project presents the comprehensive design, mathematical modeling, and implementation of a microcontroller-based programmable electronic load capable of operating in Constant Current (CC), Constant Resistance (CR), and Constant Power (CP) modes. An ESP32 serves as the core processing unit, regulating the load through a discretized Proportional-Integral (PI) closed-loop feedback mechanism to ensure stable operation amidst fluctuating input voltages. A logic-level power MOSFET (IRLZ44N) acts as the primary controllable load element, driven dynamically using Pulse Width Modulation (PWM) signals. Hall-effect current sensors and isolated voltage dividers provide real-time, high-fidelity feedback to the microcontroller. To ensure robust operational safety, an automated protection suite is embedded, featuring thermal cut-offs via an integrated temperature sensor, over- current protection, and an under-voltage lockout to protect lithium-ion test subjects from over-discharge. Furthermore, the system autonomously integrates discharge currents over time to calculate precise battery capacities (Ah), while supporting se- rial data logging for post-test graphical analysis. The proposed architecture is validated via Proteus simulation and physical hardware prototyping, proving to be a highly cost-effective, precise, and reliable instrument suitable for academic laboratories, rapid prototyping, and advanced battery performance evaluations.},
        keywords = {Electronic Load, ESP32, Battery Testing, Constant Current Mode, Constant Power Mode, PWM, MOS- FET, Thermal Protection, Data Logging, Proportional-Integral Control.},
        month = {March},
        }

Cite This Article

AFSAL, A., & K, F. M. A., & K, V., & paul, E. (2026). Microcontroller based programmable load. International Journal of Innovative Research in Technology (IJIRT), 12(10), 8238–8246.

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