CASE STUDY SNAPSHOT
Customer : Leading manufacturer of batteries, battery packs and BMSSize : > 200-1000
Project vertical : Industrial
Challenge : Our customer needed to monitor batteries deployed in remote areas using local semi-skilled workforce
Solution : Designed and developed a remote battery monitoring system with low Power IoT based monitor and BLE Based Secure Provisioning
Services & Products Availed : Turnkey Product Development, Cloud Services, SkyCase IoT Cloud
Tools and Technologies :
- Platform: NXP KW35
- Programming Language: Embedded C
- Frameworks: MCUXpresso IDE, RAPIDSEA
- Data Storage: SkyCase IoT Cloud
INTRODUCTION
Our client, a pioneer in lithium-ion battery manufacturing, specializes in powering electric vehicles, smart buildings, and solar energy systems. Their mission aligns with global sustainability goals, focusing on delivering cutting-edge energy solutions for EVs, smart building management system-controlled batteries, and rooftop solar hybrid installations.
They approached Embien Technologies with a complex challenge: to revolutionize their battery system infrastructure through advanced IoT integration. The primary objective was to develop a sophisticated IoT solution that would enable comprehensive real-time monitoring capabilities, efficient data collection mechanisms, and seamless remote management of deployed battery systems.
This case study delves into our successful implementation of an innovative remote battery monitoring system and cloud solution, leveraging cutting-edge Bluetooth Low Energy (BLE) technology for BLE Based Secure Provisioning and advanced LTE capabilities for robust cloud connectivity.
CHALLENGE
The company encountered multiple critical challenges in their operations. The foremost concern was establishing reliable real-time monitoring capabilities for their battery systems, particularly those deployed in remote locations. The absence of continuous monitoring capabilities made it extremely difficult to accurately assess battery health parameters, track performance metrics, and monitor operational conditions. This limitation frequently resulted in unexpected system failures and unnecessary maintenance interventions, leading to significant operational inefficiencies and increased costs.
The second major challenge involved the complexity of battery system deployment and configuration processes. Field technicians were spending excessive time on-site, ensuring proper battery connectivity and functionality. The existing manual configuration process was not only time-consuming but also susceptible to human error, creating additional complications in managing their expanding battery network. Furthermore, the project demanded strict power efficiency requirements, with Battery Management Systems (BMS) needing to maintain cloud connectivity while consuming less than 200mW of power.
Recognizing Embien's expertise in embedded systems and IoT solutions, the battery manufacturer sought our comprehensive expertise to develop an integrated solution that would enhance their operational productivity and system reliability.
SOLUTION
Embien's team of expert engineers developed an innovative remote battery monitoring system comprising lightweight, power-efficient firmware seamlessly integrated into their Battery Management Systems (BMS) and connected to a sophisticated cloud-based management platform.
Our solution utilized state-of-the-art Bluetooth Low Energy (BLE) and LTE technology to establish robust connectivity between the mobile application and cloud infrastructure, with BMS serving as an intelligent intermediary between the battery systems and cloud platform.
To streamline field deployment, we implemented an advanced BLE-based secure provisioning system. During production, each battery unit was assigned a unique QR code identifier. This enabled field technicians to simply scan the QR code using our custom-developed mobile application, triggering automatic battery registration and configuration for the specific user or distributor. This innovative approach significantly reduced installation time and enhanced deployment reliability.
The battery packs were equipped with advanced LTE modules, ensuring consistent cloud connectivity even in remote locations. Our Low Power IoT based monitor incorporated sophisticated data management features, including local data storage and automated synchronization capabilities for handling network interruptions. The BMS firmware was enhanced with intelligent features including comprehensive battery health diagnostics, advanced performance optimization algorithms, and predictive maintenance alerts, significantly improving battery reliability and management efficiency.
The cloud platform served as a sophisticated command center, enabling comprehensive monitoring and management of the entire battery ecosystem from a centralized interface. This advanced platform incorporated cutting-edge analytics tools for deep data analysis, automated report generation capabilities, and secure over-the-air (OTA) firmware updates, ensuring all systems maintained optimal performance with the latest features and security enhancements.
KEY BENEFITS OF WORKING WITH EMBIEN
- Technical Excellence: Our team's deep expertise in embedded systems and IoT solutions enabled us to deliver a highly optimized, power-efficient solution that exceeded the client's expectations.
- Innovative Problem-Solving: We developed creative solutions to complex challenges, such as the QR code-based provisioning system that significantly simplified field deployment.
- End-to-End Implementation: From firmware development to cloud integration, we provided a comprehensive solution that addressed all aspects of the client's requirements.
- Customization Flexibility: We offered tailored solutions that align perfectly with customer specific business requirements and technical specifications.
- Industry-Leading Security: Our implementations followed stringent security protocols, ensuring data protection at every level.
Through this successful implementation of remote battery monitoring system, Embien demonstrated its capability to deliver complex IoT solutions that address real-world challenges in the battery management industry, while maintaining high standards of quality and reliability.
CONCLUSION
The comprehensive Low Power IoT based monitor and cloud solution delivered by Embien provided the battery manufacturer with a state-of-the-art, scalable platform for remote battery system monitoring and management. The innovative combination of BLE-based secure provisioning and LTE-based cloud management enabled efficient, real-time data collection and sophisticated analysis capabilities, significantly enhancing battery product reliability and performance metrics. This solution not only addressed the manufacturer's immediate operational challenges but also established a robust foundation for future advancements in battery management technology and IoT integration, positioning them at the forefront of industry innovation.
