Remote Battery Monitoring 

As industrial equipment becomes increasingly electrified, effective battery management is crucial for maximizing uptime, reducing maintenance costs, and extending asset lifespans. However, many organizations struggle to efficiently monitor and manage their battery-powered fleets, especially when equipment is distributed across multiple locations.

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This paper presents a solution that leverages two key components:

1. Delta-Q Technologies RC Series Battery Chargers: Advanced, programmable chargers designed for industrial applications, supporting both lead-acid and lithium-ion batteries.

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2. Amplified Engineering nodeG5 Industrial Gateway: A versatile IoT gateway with CAN bus support, edge computing capabilities, and multiple connectivity options.

By integrating these devices, organizations can create a powerful remote battery management system that provides real-time insights, predictive maintenance capabilities, and optimized charging processes.

2.1 Delta-Q RC Series Battery Chargers

The Delta-Q RC Series includes models RC900, RC1000, and RC1200, offering charging solutions for 24V, 36V, and 48V battery systems with power outputs ranging from 900W to 1200W. Key features include:

- IP66-rated rugged aluminum enclosure for durability in harsh environments

- Support for both lead-acid and lithium-ion battery chemistries

- CAN bus communication for integration with telematics and battery management systems

- Customizable charging algorithms to optimize battery life and performance

- Global input voltage compatibility (85-270 VAC)

- High efficiency (up to 93% peak) for reduced energy consumption

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2.2 Amplified Engineering nodeG5 Industrial Gateway

The nodeG5 is a powerful edge computing device designed for industrial IoT applications. Key features include:

- Dual CAN bus ports supporting J1939 and OBD2 protocols

- 4G/LTE cellular connectivity and GPS (optional)

- Edge processing capabilities with support for Docker containers and TensorFlow Lite

- Integrated clients for major cloud platforms (AWS, Azure, Ubidots)

- Robust aluminum enclosure with wide operating temperature range (-40°C to +65°C)

- Multiple I/O options including Ethernet, USB, and HDMI

3.1 Data Flow

The integrated solution follows this general data flow:

1. The Delta-Q RC Series charger collects battery data during the charging process.

2. Battery and charger data is transmitted to the nodeG5 gateway via CAN bus (J1939 protocol).

3. The nodeG5 processes and aggregates the data, applying edge computing algorithms if needed.

4. Processed data is securely transmitted to cloud services using 4G/LTE or Ethernet connectivity.

5. Cloud platforms provide data visualization, analytics, and integration with other business systems.

3.2 CAN J1939 Communication

The CAN J1939 protocol serves as the primary communication method between the RC Series charger and the nodeG5 gateway. Key data points transmitted include:

- Battery voltage and current

- State of charge (SOC)

- Charging status and mode

- Battery temperature (if sensor equipped)

- Fault codes and warnings

3.3 Edge Computing on nodeG5

The nodeG5's edge computing capabilities allow for local processing of battery data, enabling:

- Real-time analysis of charging patterns

- Detection of potential battery issues before they become critical

- Data compression and filtering to optimize cellular data usage

- Execution of custom algorithms for specific application requirements

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3.4 Cloud Connectivity Options

The nodeG5 offers flexible cloud connectivity options:

- Built-in clients for AWS IoT Core, Azure IoT Hub, and Ubidots

- MQTT protocol support for integration with other cloud platforms or on-premises servers

- Secure data transmission using TLS encryption

5.1 Remote Monitoring

- Real-time visibility into battery and charger status across distributed fleets

- Automated alerts for low battery conditions or charging issues

- Historical data analysis for performance trending and optimization

5.2 Predictive Maintenance

- Early detection of battery degradation based on charging patterns

- Identification of charger malfunctions or inefficiencies

- Scheduling of proactive maintenance to prevent unexpected downtime

5.3 Fleet Management

- Optimization of charging schedules to reduce peak energy demand

- Tracking of battery usage patterns to inform equipment rotation strategies

- Integration with asset management systems for comprehensive fleet oversight

5.4 Energy Optimization

- Analysis of charging efficiency across different locations and equipment types

- Identification of opportunities for energy savings through optimized charging algorithms

- Support for demand response programs by controlling charging based on grid conditions

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5.1 Security

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- Ensure proper configuration of CAN bus networks to prevent unauthorized access

- Utilize the nodeG5's built-in security features, including TLS encryption for data transmission

- Implement appropriate access controls and authentication mechanisms in cloud platforms

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5.2 Scalability

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- Consider cellular data plans and costs for large-scale deployments

- Leverage the nodeG5's edge computing capabilities to minimize cloud processing requirements

- Design cloud architecture to handle potential rapid growth in connected devices and data volume

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5.3 Data Management

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- Develop a data retention policy that balances analytical needs with storage costs

- Implement data aggregation and summarization strategies for long-term trend analysis

- Ensure compliance with relevant data privacy regulations, especially for global deployments

The integration of Delta-Q RC Series battery chargers with Amplified Engineering's nodeG5 industrial gateway provides a powerful solution for remote battery management in industrial applications. By combining advanced charging technology with robust IoT connectivity and edge computing capabilities, organizations can achieve significant improvements in operational efficiency, equipment reliability, and energy optimization. As the industrial landscape continues to evolve towards greater electrification and connectivity, this integrated approach offers a scalable foundation for future-proofing battery-powered fleets.