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Full-Stack Platform for EV Battery Health - Predictive Maintenance with IoT and Machine Learning

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  • Full-Stack Platform for EV Battery Health - Predictive Maintenance with IoT and Machine Learning

Challenges:

EV fleet managers struggled with limited visibility into battery degradation, leading to unexpected failures, reduced operational efficiency, and higher maintenance costs.

Industry

AI Solutions

Solutions:

Built a full-stack web and mobile platform integrated with IoT-enabled battery monitoring. Applied machine learning models to predict Remaining Useful Life (RUL) of EV batteries and support data-driven maintenance planning.

Result:

  • 37% improvement in battery lifespan forecasting accuracy
  • Preventive maintenance scheduling implemented across the fleet
  • Reduced downtime and extended battery life cycles

Location:

India

Introduction

Electric vehicle fleet operators rely on battery performance for consistent service delivery and cost efficiency. Without real-time insights into battery health, managers face increased risk of breakdowns, reduced lifespan, and costly repairs. This case study examines how our IoT-integrated, AI-powered platform delivered predictive insights to help fleet operators optimize maintenance, extend battery life, and improve operational reliability.

Problem

Fleet managers lacked the tools to continuously monitor and analyze EV battery performance. Existing systems provided only basic metrics, failing to predict degradation trends or estimate remaining useful life. This reactive approach led to premature replacements, unplanned downtime, and higher operational costs.

Solution

We developed a secure, scalable platform with:

  • 1. IoT Data Integration: Collected real-time performance metrics from EV battery management systems via IoT pipelines.
  • 2. Machine Learning Forecasting: Created ML models to accurately predict RUL based on usage patterns, temperature, charging cycles, and environmental factors.
  • 3. Preventive Maintenance Scheduling: Generated automated maintenance alerts to address battery issues before failures occurred.
  • 4. Web & Mobile Dashboards: Delivered intuitive interfaces for fleet managers to view battery health, forecasts, and maintenance logs in real time.
  • 5. Scalable Full-Stack Architecture: Ensured seamless integration with different EV manufacturers and fleet management systems.

Implementation

  • Data Pipeline Development: Built IoT-enabled pipelines to collect, clean, and process battery telemetry.
  • Model Training: Applied regression and time-series ML models trained on historical battery performance data.
  • Platform Build: Developed responsive web and mobile apps for accessibility on the go.
  • Integration: Connected with existing fleet management tools to streamline workflows.
  • Testing & Rollout: Conducted pilot testing with selected fleet operators before scaling platform deployment.


Result

  • Forecast Accuracy: Improved battery lifespan predictions by 37%, enabling proactive decision-making.
  • Maintenance Efficiency: Adopted preventive maintenance scheduling, reducing unplanned downtime.
  • Cost Savings: Extended battery life cycles, reducing premature replacement expenses.

Conclusion

Trustometer equips non-profits with a powerful AI-driven framework for ensuring transparency, boosting donor trust, and reducing operational risks. By combining beneficiary verification, sentiment analysis, and governance scoring, it transforms the way charitable organizations manage trust and compliance, paving the way for more ethical and efficient operations.

Saudi Arabia

Riyadh

Prince Mohammed Ibn Salman Ibn Abdulaziz Rd, Riyadh 13315, Saudi Arabia

Brussels

Belgium

Veeboslaan 2 Sterrebeek 2933,
Brussels, Belgium

India

Hyderabad-HQ

13-6-434/B/45/2, Omnagar,
Hyderabad TS-India, 500008

NL

The Hague

Wilhelmina van Pruisenweg
35, 2595 AN, The Hague, Netherlands

US

New York

45 Main Street, Suite 1000,
Brooklyn, NY 11201, United States

India

Ujjain

Crystal Tower, Freeganj, Ujjain,
MP 456010, India

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