How a Global EV Battery Manufacturer Reduced Manual Maintenance Costs by 50% and Time Spent by More than 80%

Overview

A leading EV battery manufacturer with installations in buses across Europe, needed an IoT solution to monitor their battery’s performance parameters over its lifetime. They wanted insights into user behavior to gauge battery life and overall battery health & performance. Using Datakrew’s Battery Diagnostics & Analytics solution OXRED, the client was able to remotely monitor user behavior and get prior alerts in case of faults.

Client Profile

Our client offers closed-loop, end-to-end Energy Storage Solutions (batteries) for a variety of e-mobility, specialty, and stationery applications. Their primary focus is on the manufacturing, and R&D of Lithium-ion Battery (LIB) materials, battery cell manufacturing, and integration of battery systems. They are a leading innovator in Lithium-Ion cell technology.

Problem

Our client wanted to close the feedback loop of performance parameters over its lifetime. They also wanted to track real-time user behavior such as driving style, charging and discharging patterns, and battery handling to extend battery life and avoid potential battery damage. Alerts and recommendations were needed to inform them of potential defects and fire hazards. Our client did not have access to historic data which meant that they could not analyze the trends. The warranty was fixed based on the age of the battery as parameters like usage and charging cycles were not accessible.

Solution

Datakrew introduced OXRED, monitoring, and alerting system. With OXRED, the collection, monitoring, and accumulation of data were possible in real-time.

OXRED collected data from both EVs and charging stations and a quick analysis of the EV battery was provided. The analysis was done in real-time, whenever an EV car was charging or discharging. This analysis identified the cell’s performance levels and detected battery anomalies. This helped in gauging potential fire hazards. And since OXRED is hardware agnostic it can work with any EV using any BMS.

Results

With OXRED capturing, analyzing, and storing real-time data was feasible. Since previously stored data was accessible, it was easier for the client to make reliable and data-backed decisions. Access to data history was also used to analyze trends and thereby improve the battery design. The client was able to get alerts before mishaps through our Battery Analytics Platform. This acted as an add-on safety-based service for the end-user. Our client was able to generate add-on services by offering services like remote monitoring, analysis, etc.