IoT-Based Real-Time Battery Health Monitoring System for Electric Vehicles

Author

Dr. M. Vinay Kumar, N. Pragnya, K. Hemanth Kumar, N. Thanusri

Abstract

The performance, reliability and safe operation of an electric vehicle depend strongly on the condition of its battery pack. Continuous observation of electrical and thermal parameters can help identify abnormal operating conditions and support timely maintenance. This paper describes the development of a low-cost Internet of Things (IoT)-enabled battery monitoring prototype based on an ESP32 microcontroller. A resistor-divider circuit is used to measure pack voltage, while an INA219 sensor provides bus-voltage and current measurements through the I²C interface. A DS18B20 digital sensor is included in the design for temperature measurement. The controller processes the acquired readings, calculates instantaneous electrical power and estimates the battery State of Charge (SOC) using Coulomb counting. The measured information is made available through a browser-based dashboard hosted by the ESP32 and accessed over the local Wi-Fi network. The prototype was evaluated using a 3-series (3S) lithium-ion battery pack. During the reported test session, the dashboard displayed pack voltages of 11.74 V and 11.66 V, discharge currents of 0.09 A and 0.18 A, and corresponding power values of 1.09 W and 2.04 W. The estimated SOC remained at 80%. The temperature sensor was reported as disconnected during these measurements; therefore, temperature measurement and over-temperature protection were not experimentally validated. The results demonstrate the feasibility of browser-based monitoring of selected battery parameters using inexpensive embedded hardware.

Keywords

Internet of Things, electric vehicles, battery monitoring, ESP32, INA219, DS18B20, State of Charge, Coulomb counting, web dashboard.

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References

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