Case Study:  Communication Over Power Lines

Smart data transmission over existing power infrastructure — no new wires needed.

📝 Project Overview

This Communication Over Power Lines module was engineered to enable reliable, high-speed digital communication through existing AC power lines — eliminating the need for additional data cabling in industrial and commercial environments. With advanced signal modulation, noise filtering, and robust galvanic isolation, the system is ideal for retrofitting smart connectivity into legacy power setups.

🧩 System Architecture

🛠 Two-Board Modular Design

1. Power Interface Board

  • Signal Isolation: Inductive coupling for safe and efficient signal transfer

  • Filtering & Coupling:

    • Band-pass filtering using precision capacitors

    • High-frequency blocking via integrated inductors

  • Galvanic Isolation: Clean separation between AC power and communication signal paths

2. Communication Board

  • Signal Processing: Embedded Analog Front-End (AFE) ICs for ADC/DAC tasks

  • Modulation: Real-time encoding and decoding of digital signals over power lines

  • I/O Interfaces: Ethernet (GMII), CAN, and USB for integration into larger control systems

⚙ Technical Highlights

  • 🔁 Inductive Coupling: Tuned for optimal signal transfer while maintaining safety and electrical isolation

  • 🧹 Noise Handling: Advanced filtering and conditioning for stable performance over noisy AC lines

  • 📶 EMC/EMI Compliance: Designed to meet industrial interference standards

  • 🛠 Integration-Friendly: Supports seamless networking across distributed systems — no extra wiring needed

🌍 Applications

  • 🔧 Industrial Automation – Communication over legacy wiring in large-scale plants

  • ⚡ Smart Grid Systems – Real-time energy usage and monitoring

  • 🏢 Commercial Retrofits – Add communication capabilities to existing electrical layouts without new installations

✅ Outcome

Delivered a reliable and scalable solution that minimizes infrastructure cost while enabling modern connectivity — ideal for smart building, energy management, and industrial control applications.