CASE STUDY — EV BATTERY TELEMETRY & FLEET OS

Real-time telemetry cockpit
engineered for commercial EV fleets & microgrids.

High-throughput IoT time-series streaming, millisecond-grade battery degradation telemetry, and autonomous charging orchestration across 5,000+ commercial fleet assets.

PLATFORM VELOCITY: PRODUCTION IOT TELEMETRY ARCHITECTURE
120K/s IoT Events Ingested
<25ms Telemetry Latency
+22% Battery Pack Lifespan

Orchestrating mission-critical energy and battery telemetry at scale.

Commercial fleet operators faced compounding losses due to unpredicted cell degradation, demand-charge penalties, and disconnected telematics systems. Arcrux built a unified cockpit that streams real-time cell state, thermal gradients, and intelligent depot charging algorithms into a responsive operational HUD.

Industry Electric Vehicles & Clean Tech
Disciplines IoT Telematics UX & High-Scale Systems
Timeline 14 Weeks (Discovery to Production)
Target Platforms Desktop Dispatch HUD & In-Vehicle Tablets

Millisecond-grade cell diagnostics across 5,000+ battery packs.

Engineers and fleet controllers inspect individual cell voltages, pack impedance, and thermal cooling loops in real time. Anomalies trigger deterministic alerts before thermal runaway or premature cycle degradation occurs.

Sub-25ms Stream Latency Pack Thermal Profiling State of Health (SoH) Tracking CAN Bus Ingestion
Real-time EV battery pack diagnostics and cell degradation telemetry

Dynamic peak shaving. $1.4M saved in annual utility tariffs.

Automated charging schedules synchronize fleet readiness deadlines with utility time-of-use (TOU) rates and on-site solar BESS generation, automatically shaving demand peaks without delaying vehicle departures.

Automated Peak Shaving Depot TOU Optimization Route Readiness Guardrails Solar / BESS Balancing
Commercial EV fleet charging depot schedule and power optimization cockpit

Physics-informed range models calibrated to payload & terrain.

Replaced static OEM estimates with dynamic physics-informed ML models that account for ambient temperature, elevation profiles, and cargo mass to guarantee non-stop delivery cycles.

Physics-Informed ML Terrain-Calibrated Range Degradation Modeling Zero Dead-On-Road Events
Predictive fleet asset health and manufacturing operations dashboard

Engineered for high-intensity dispatch rooms & mobile cockpits.

Crafted a resilient dark/light design token architecture with high-visibility color-coding for warning states, critical threshold indicators, and legible numerical gauges that remain readable in direct sun or low-light dispatch rooms.

High-Density Data Tokens Sub-Pixel Vector Gauges Glare-Resistant Palettes Instant Keyboard Navigation
Industrial telemetry component system and hardware sensor visualization tokens

Quantified operational impact across 5,000+ commercial vehicles.

Within nine months of fleet rollout, VoltPulse reduced battery replacement capital costs, eliminated unexpected en-route breakdowns, and drastically reduced depot energy bills.

+22%
Pack Lifespan

Optimized charge cycles extended multi-cell warranty lifetime by 2.4 years.

-38%
Depot Energy Cost

Automated TOU peak shaving slashed utility demand penalties by $1.4M.

0
Dead-On-Road

Predictive payload range calculations prevented stranded vehicles across 1.2M miles.

120K/s
Stream Ingestion

Sustained real-time telemetry events without dropped packets or socket lag.

“VoltPulse gave us unprecedented visibility into every battery pack in our fleet. We moved from reactive fire-fighting to proactive, automated energy management that directly reduced our operational overhead.”

VP
Director of Fleet Electrification & Infrastructure Global Logistics & Transport Enterprise
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