Case Study: Xerotech
Background
Off-road electric vehicles designed for extreme environments – such as construction sites, mining operations, and military applications, require high-capacity lithium-ion battery packs built to withstand intense operational stresses, including high vibration, wide temperature swings, and rugged terrain.Xerotech addressed these challenges through its leading battery system designs.
While the mechanical systems performed reliably, Xerotech identified a critical gap in their ability to monitor battery health and performance in real time—particularly during high-stress conditions. Their existing data logging systems, which only captured one data point per second, lacked the precision and responsiveness needed to manage and safeguard high-power batteries operating at the edge of their limits.
Recognising the strategic importance of data in ensuring performance and safety, Xerotech approached ODOSOLUTIONS (ODOS). With proven expertise in high-frequency vehicle data logging and cloud-based analytics, ODOS was the ideal partner to help design a more responsive system- one capable of monitoring fast-changing conditions, generating alerts, and enabling smarter battery management decisions in even the harshest operating environments.
Challenges
Xerotech faced a series of critical challenges in their efforts to ensure the safety, reliability, and longevity of their battery systems. One of the most pressing issues was the inadequacy of their existing data logging infrastructure. The original system recorded only one battery data point per second, which made it difficult to detect fast fluctuations during high discharge events, limiting visibility into performance and delaying fault detection. Without real-time insights, diagnosing battery issues often took longer than necessary, resulting in costly downtime and operational risk.
Overdischarge presented a particular concern. Without the ability to track or alert for these events, batteries could be damaged irreversibly posing safety risks and reducing long-term efficiency. These issues were compounded by the environments in which Xerotech vehicles operated, where harsh conditions and limited access to support meant that early warning and proactive management were essential.
Our solution
Approach
ODOS took a comprehensive approach to solving these challenges. Working closely with Xerotech’s engineering team, ODOS assessed the limitations of the existing system and proposed an upgraded solution based on a high-frequency data logging platform capable of capturing 10 readings per second – offering ten times the resolution and insight.
To ensure the solution met the client’s requirements, modifications were made to an off-the-shelf data logging platform, adapting it for use in harsh environments. Additionally, ODOS designed the system to not only capture more frequent data points but also to issue real-time alerts when certain thresholds, such as the risk of overdischarge, were detected. This would allow Xerotech to proactively manage battery health and avoid potential failures.
Implementation
The implementation process began with the integration of the upgraded data logging system into Xerotech’s vehicle platforms. ODOS ensured the hardware was mounted securely within the vehicle’s cabin, protecting it from external environmental factors while maintaining a reliable connection to the vehicle’s battery pack.
The team worked directly with Xerotech’s engineering team to fine-tune the data points that would be monitored most closely, focusing on key parameters such as voltage levels, current draw, and temperature fluctuations. The new system was also designed with an intuitive user interface, allowing vehicle operators to easily interpret the data and receive notifications if the battery neared an unsafe condition.
Once the system was in place, ODOS ran a series of tests under various operational scenarios to ensure
the data logging system provided accurate, real-time information. The system’s alert functions were calibrated to notify operators of issues like overdischarge, helping to prevent potential damage and ensuring vehicles could be safely managed even in remote or high-risk locations.
This solution was fully deployed across Xerotech’s fleet of off-road electric vehicles.
Results and impact
Quantitative outcomes
Increased data capture: Data logging frequency increased from one reading per second to 10 readings per second, providing a much more granular level of insight into battery performance. This allowed for more accurate trend analysis and better decision-making regarding battery management.
Reduction in safety incidents: By implementing the overdischarge alerts, Xerotech saw a marked reduction in battery-related incidents. Vehicles are now able to detect overdischarge events earlier, allowing for more proactive measures and fewer instances of irreversible damage.
Improved battery health: With more frequent monitoring, Xerotech was able to optimise the charging cycles and operational use of their batteries, extending their lifespan and ensuring better reliability for customers.
Operational efficiency: Real-time diagnostics reduced troubleshooting time and downtime, enabling quicker issue resolution and greater overall vehicle uptime.
Qualitative benefits
Customer satisfaction: The ability to monitor battery performance more effectively and alert customers to potential issues enhanced Xerotech’s reputation as a reliable, forward-thinking manufacturer.
Improved customer education: Xerotech has also used the insights from the enhanced data logging system to educate customers on proper battery management practices, such as avoiding deep discharge.
Sustainability: By ensuring batteries are better managed and have a longer lifespan, the solution contributed to the sustainability efforts of Xerotech, reducing the need for frequent replacements and minimising the environmental impact of battery disposal.
Client testimonial
”ODOSOLUTIONS provided us with a game-changing solution that enhanced our ability to monitor and manage battery performance. The real-time data logging and overdischarge alerts made a huge difference in both the safety of our vehicles and the satisfaction of our customers. The improved visibility into battery health allowed us to deliver even better performance and reliability, which is key for operations in tough environments.”
Kiran Bachewar, Xerotech
Contact Us
Website: https://odosolutions.com/
Email: sales@odosolutions.com