The customer faced a problem with battery degradation in e-bikes due to incorrect charging practices. If batteries were charged to 100% and left fully charged for extended periods, they deteriorated, leading to costly replacements. The objective was to create a system that would automatically stop charging at a preset level, usually around 80%, to extend battery life. Additionally, the system required easy monitoring and control of charging, both locally and remotely, to prevent charging beyond daily limits.
We developed a battery charging management system combining hardware and software elements. The core of the system is Raspberry Pi with a 433 MHz radio module, simulating remote control of outlets to start and stop charging. We integrated this system into the customer’s FileMaker application, where users can set charging schedules or stop charging early, preventing overcharging. The Raspberry Pi acts as a web server, receiving HTTP requests from FileMaker, which then sends signals to smart outlets that control the charging.
For hardware control, a push-button switch was placed on the charger to start charging without needing a mobile device or computer. Additionally, a safety feature was implemented to automatically stop charging daily at a predefined time unless the user provides a different command.
The system also logs all charging activities for battery health monitoring, allowing the customer to track charging frequency and duration, which can then be compared with battery performance over time. After a year of use, the system demonstrated a significant improvement in battery lifespan, confirming that proper charging management effectively prevented degradation.
