Electric Vehicle Data Logger - Cloud Battery Telematics

Electric Vehicle Data Logger Battery Management

Managing batteries in electric vehicles or stationary grids is a challenge.

But, what if you could monitor your EV batteries across entire vehicle fleets
- directly from your own cloud server?

Below we detail the EV battery industry, trends, the urgency/benefits of battery telematics - and how to get started with the CL3000 electric vehicle data logger.



THE ELECTRIC VEHICLE BATTERY (EVB) INDUSTRY

Electric Car Sales 2040 Global Volume Share

KEY FACTS & FIGURES



Electric Vehicle Types Industry Global Market

Electric Vehicle Sales by Type 2040 Volume Global
Electric Car Lithium-Ion Battery

Electric Cars: With the advances in lithium-ion batteries, electric cars are rapidly growing with e.g. 2017 Q3 showing a 63% growth YoY vs. 2016. By 2040, there’ll be 560 mn electric cars on the road (33% of all cars)

Electric Bi-Cycle Lithium-Ion Battery

Electric Bi-Cycles: Already today a huge market of ~36 mn+ units sold globally (95%+ in Asia) - with e.g. 200 mn in use in China. Western EU see ~1.6 mn units sold annually, while North America is only at ~0.2 mn units per year

Electric Motorcycle Bike Scooter Lead Acid Battery

Electric Motorcycles & Scooters: As for e-Bikes, electric motorcycles & scooters are biggest in Asia, though growing fast in India. Significant advances are made in the technology, boosting speed and range massively in recent years

Electric Forklift Fuel Cell Battery

Electric Forklifts: Today, 60%+ of forklifts are electric (Class 1, 2, 3), up from 40% 30 years ago - with 600k+ electric units sold globally in 2017. This drives the markets for lead-acid, lithium-ion and fuel cell batteries

Electric Truck e-Truck Tesla Semi

Electric Trucks: Electric trucks are expected to comprise 15% of all trucks by 2030 with e.g. the recent Semi launch by Tesla paving the way for eTrucks within also the heavy-duty segment

Electric Bus e-Bus Lithium Battery

Electric Buses: Buses go electric faster than other vehicles. In Shenzhen, China, all public buses are now 100% electric - counting a bus fleet of 16k+ for that city alone. Globally there are ~385k electric buses (99% in China)

Electric Automated Guided Vehicle AGV

Electric AGVs: Electric Automated Guided Vehicles (AGVs) are portable warehouse robots. While still a small segment, the rise of e-commerce and Industry 4.0 may drastically boost their relevance and volume




EV Batteries Lithium-Ion Lead Acid Nickel Fuel Cells

ELECTRIC VEHICLE BATTERY TYPES

Below we briefly recap the main battery types used in electric vehicles - expand to learn more!

Various batteries are used in electric vehicle applications, but the most common are listed below:

Lead Acid: Deep-cycle lead acid batteries represent a fairly mature and low cost technology. However, they also require frequent replacement and have a very low energy density (30-40 Wh/kg). Use cases incl. forklifts, bi-cycles and cars.

Nickel-Metal Hydride (NiMH): Also seen as a mature technology, this EV battery type comes with a better energy density than lead-acid (30-80 Wh/kg) and offers exceptional life-time. However, they are less efficient and have a number of other downsides.

Lithium-Ion (Li-Ion): Today, li-ion batteries are used in most EVs due to their 200+ Wh/kg density and strong efficiency specs. Recent variants reduce costs massively, while boosting lifetime towards 10-40 years.

EV Battery Electric Lead-Acid Lithium-Ion

Fuel Cells: Fuel cells play an increasing role in powering e.g. electric forklifts, with big players like Walmart and Amazon making the shift. They replace or work with a rechargeable battery and are emission-free, generating only heat and clean water. Advantages include faster recharging, lighter infrastructure, temperature stability and better life-time costs.







The Vital Role of Battery Data

To recap: There is no doubt that EV batteries are the future.
However, batteries need proper management to operate safely and efficiently.

Today, that's handled via the Battery Management System (BMS), acting as the "brain" of the battery". Due to the importance, we've detailed the BMS below - but feel free to skip it if you're already familiar with this.

BMS Battery Management System EV Vehicle CAN Bus

The BMS is an electronic system that integrates with rechargeable batteries to monitor critical data parameters.

These include e.g. state, voltage, current and temperature.

Based on the data, the BMS performs vital tasks:

  • Keeping the battery inside it's safe operating area
  • Monitoring & reporting the battery state (SoC, SoH, ...)
  • Balancing cells to ensure a similar state of charge
  • Prolonging the life of the battery
  • Communicating with e.g. chargers or external devices
Battery Management System Hardware Monitoring

EXAMPLE: ROLE OF BMS IN CHARGING

In lithium-ion batteries, overcharging can lead to overheating - potentially resulting in catastrophic events. Conversely, discharging the battery below e.g. 5% capacity can lead to permanent capacity reduction.

In both cases, the BMS manages the charge to avoid thresholds being passed.

An example of a more advanced use of BMS is in “intelligent batteries”. Here, the BMS provides data to an “intelligent charger” on the battery’s specs, condition and usage history - allowing the charger to perform optimal charging.


In automotive context, the BMS needs to be able to communicate with other sensors and ECUs in the vehicle

As CAN bus is the standard in automotives, it's also the de facto standard for EV batteries.

As such, it's possible to record data from the BMS of most EV batteries using a CAN bus data logger.

Specifically, batteries often rely on the CAN bus protocols SAE J1939 or CANopen - providing data on a range of parameters, e.g. temperature, pack voltage, cell voltage, current, errors, SoC.

For more details on the technical aspects of BMS, we recommend the below reading:


Just like vehicle telematics has become huge in recent years, EV battery management is increasingly moving to the cloud.

Below we list some of the main trends enabling this - and the potential benefits.


Today, most EV batteries are "closed systems":

The EV batteries generate tons of invaluable data - but the data is not truly utilized.

However, just like the rising trend of connected cars, there is a rising demand for connected batteries.
Four key trends are enabling this - click below to learn more:


Electric Vehicle Growth Trend Fleet Battery Management

Rise of EVs: As EVs rapidly grow towards 2040, there will be a need for integrating battery telematics into commercial vehicle fleets - across trucks, vans, buses, forklifts, AGVs and more. As this market matures, so will the use of battery telematics

150+ mn
EVs by 2040
(vs 40 mn in 2017)

EV Cloud Battery Trend EV Battery Management System

Rise of Cloud: Like vehicles, batteries provide tons of data that need storage and fast processing - but with the rise of cloud servers, this becomes increasingly simple & low cost. Cloud computing also enables far more advanced BMS methods

$300 bn
public cloud market in 2021
(vs ~150 bn in 2017)

Internet of Things IoT Monitoring EV Battery Loggers IoT Electric Bus Fleet

Rise of IoT: Collecting battery data via WiFi / 4G has previously been costly and difficult. However, the rise of the Internet of Things (IoT) now also brings low cost CAN bus IoT devices that easily enable the transfer of the battery big data

5+ bn
B2B IoT devices by 2020
(vs ~2.5 bn in 2017)

AI Artificial Intelligence ML Trend

Rise of AI: Finally, the use of advanced analytics and Artificial Intelligence (AI) for EVBs has been beyond the existing BMS systems - but with the full set of big data in the cloud, next level battery optimization will be possible - and key to stay competitive

50%+ CAGR
in AI enterprise market
(~$1 bn in '17 to $30+ bn in '25)

Or, as stated in the below article published in the Power and Energy Magazine IEEE (2017):

"The continuing proliferation of and advances in information and communication technologies, development of powerful cloud computing capabilities, and a growing Internet of Things will significantly enhance or even transform the concept of battery management, as modeling and control of thousands of cells in large-scale battery storage will become easier."

- Hu, C. Zou, C. Zhang, Y. Li, “Technological Developments in Batteries: A Survey of Principal Roles, Types & Management Needs




In short, cloud battery telematics is becoming increasingly feasible.

But why do it? Below we list 9 major strategic benefits:




Top 9 Benefits of Battery Telematics




EV Battery Telematics Application Example



Electric Forklift Battery Monitoring Cloud

MONITORING FORKLIFT BATTERIES

Segment: Lead acid batteries, OEMs (forklifts)
Hotspot: Warehouse WLAN WiFi hotspot
Data Frequency: Intra-daily
Challenge: Monitoring battery performance in the field

LeadBats Co is a lead-acid battery manufacturer, producing batteries for use in electric forklifts.

As part of their battery offering, they install a CL3000 WiFi CAN bus data logger in all batteries to record data while the batteries are in active use at customer warehouses. The CL3000s connect via warehouse WiFi WLANs and send it to the OEM cloud server.

This provides LeadBats with data from hundreds of batteries - which is used for KPI dashboards, remote troubleshooting, performance optimization - and much more.

Electric Car Data Logger Lithium-Ion

FIELD TESTING PROTOTYPE EV

Segment: Lithium-ion batteries, OEMs (cars)
Hotspot: Cellular USB hotspot (3G/4G)
Data Frequency: Near real-time
Challenge: Speed up EV development cycles

ELECTRA is a high-profile electric car manufacturer with big ambitions. To meet the aggressive ELECTRA4 release date, the OEM needs to deploy & monitor a large prototype fleet.

To collect data from their field testing, the OEM installs a CL3000 & 4G USB hotspot in each car, sending data in 1 MB packets to their cloud server for analaysis.

From here, the OEM can analyze diagnostic trouble codes, battery performance and quickly identify issues. By gathering data at a massive scale, the OEM greatly speeds up the development and release the ELECTRA4 on-time.




HOW TO GET STARTED WITH BATTERY TELEMATICS?

Getting started with cloud battery management can seem difficult - but it doesn't have to be.
Below we list three early considerations to make before implementation - and recommended next steps:


3 EARLY STAGE CONSIDERATIONS


Once you've reviewed the above, we propose below next steps to get started:

  1. Select a CAN bus data logger for trials
  2. Design a small proof-of-concept (incl. a very narrow use case)
  3. Do a PoC on data collection, conversion & processing
  4. Develop a bare-bones application script PoC in the cloud
  5. Scale the PoC to a full segment (BU, country, warehouse, ...) and review
  6. If successful, scale up step-by-step in breadth and use case sophistication

Below we outline the benefits of using a CL3000 WiFi CAN logger for your battery telematics.

CL3000 EV Battery Data Logger



WHY USE THE CL3000 CAN LOGGER?

The CL3000 is a low cost and simple-to-use wireless CAN bus analyzer.
It's very popular amongst EV battery OEMs for telematics - and below we list some of the main reasons:





Ready to try out the CL3000 in your EV battery fleet?
Then learn more about our WiFi CAN logger below!






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