Features
Field Control & Charging Management
Control Modes
- Standard Mode: Traditional voltage/current regulation with safety overrides
- Learning Mode: Adaptive thermal management that learns safe operating limits
- Manual Override: Direct duty cycle control for testing and troubleshooting
- Force Float Mode: Precision zero-current battery maintenance charging
- Weather Mode: Solar-aware charging that disables alternator when sufficient solar available
- Limp Home Mode: Emergency operation with reduced functionality and conservative limits
Charging Control
- Multi-Stage Charging: Automatic bulk/float transitions with configurable voltage targets
- 20-Point RPM Curves: Engine speed-dependent current limiting for optimal power delivery
- Dual Current Targets: Separate Hi/Low mode settings with instant switching
- BMS Integration: Digital input for Battery Management System override protection
- Temperature Compensation: Real-time thermal feedback with graduated field reduction
Learning Algorithm
- Thermal History Tracking: Remembers overheat events and applies progressive penalties
- Neighbor Learning: Adjusts adjacent RPM points when overheating occurs
- Automatic Recovery: Gradual current increases during extended safe operation
- Persistent Memory: Learning data survives power cycles and firmware updates
Sensor Systems & Monitoring
Measurements
- Dual Battery Voltage: INA228 (±0.1% accuracy) + ADS1115 with cross-validation
- High-Resolution Current: 16-bit measurements with microamp sensitivity
- Temperature Monitoring: Digital OneWire DS18B20 sensors (±0.5°C) + analog thermistor
- Engine RPM: Configurable magnetic pickup or alternator stator tap sensing
- Barometric Pressure: BMP390 sensor for altitude and weather monitoring
Data Quality & Reliability
- Sensor Freshness Tracking: Real-time monitoring of data age with staleness indicators
- Automatic Fallback: Seamless switching between sensor sources on failure
- Range Validation: Physical limit checking prevents invalid readings
- Cross-Validation: Disagreement detection between redundant sensors triggers safety shutdown
Battery Management System
State of Charge (SOC) Calculation
- Coulomb Counting: Amp-hour integration with floating-point precision
- Peukert Correction: Capacity adjustment for high discharge rates
- Charge Efficiency: Configurable charging losses (85-99% for different battery types)
- Full Charge Detection: Multi-parameter detection using voltage, current, and time criteria
- Dynamic Calibration: Automatic shunt gain correction based on full charge cycles
SOC Tracking
- Comprehensive Energy Logging: Charged/discharged energy totals with Wh precision
- Fuel Consumption Estimates: Calculated diesel usage based on alternator energy output
- Runtime Statistics: Engine hours, alternator on-time, cycle counting
- Historical Analysis: Persistent storage of operational data across power cycles
Communication & Integration
Marine Network Integration
- NMEA2000 (CAN): Full bi-directional connectivity with standard marine electronics
- NMEA0183: Serial data parsing for legacy GPS and navigation equipment
- Victron VE.Direct: Native integration with Victron battery monitors and charge controllers
- GPS Integration: Automatic position data from NMEA sources for weather services
Wireless Connectivity
- Dual WiFi Modes: Access Point (hotspot) or Client (connect to ship's network)
- GPIO Mode Selection: Hardware pins select operational mode during startup
- Intelligent Reconnection: Exponential backoff algorithm with signal strength awareness
- Captive Portal: Automatic WiFi configuration interface for easy setup
Web Interface & Real-Time Data
Live Monitoring Dashboard
- Real-Time Streaming: 170+ parameters updated every 50ms
- Interactive Plotting: Four simultaneous time-series plots with configurable scales
- Performance Monitoring: CPU load, memory usage, loop timing, and system health
- Alarm Status: Visual indicators for all alarm conditions with historical logging
Configuration Management
- 80+ Configurable Parameters: Complete system customization via web interface
- Immediate Effect: Settings changes apply instantly without restart
- Password Protection: SHA-256 secured access control for all configuration changes
- Factory Reset Options: Individual parameter or complete system restoration
Safety & Protection Systems
Multi-Layer Protection
- Hardware Overvoltage: INA228 independent protection with <1ms response
- Emergency Field Collapse: Software voltage spike detection with immediate shutdown
- Temperature Limits: Progressive field reduction with emergency cutoff
- Current Limiting: Battery and alternator current protection with user limits
- Watchdog Protection: 15-second hang detection with automatic restart
Fault Detection & Recovery
- Sensor Validation: Automatic detection of failed or disconnected sensors
- Graceful Degradation: Continued operation with reduced functionality on failures
- Cross-Sensor Validation: 0.1V disagreement between voltage sensors triggers shutdown
- Automatic Recovery: Self-healing from temporary faults and communication failures
Advanced Features
Alternator Lifetime Modeling
- Physics-Based Calculations: Arrhenius equation modeling for insulation degradation
- Component Life Tracking: Separate modeling for windings, bearings, and brushes
- Thermal Stress Integration: Continuous tracking of temperature exposure effects
- Predictive Warnings: Remaining component life estimates with color-coded indicators
Weather Integration
- Automatic Weather Data: GPS-based solar irradiance forecasting
- Multi-Day Analysis: 3-day solar output predictions for charging decisions
- Smart Charging: Disables alternator when sufficient solar energy predicted
- Open-Meteo API: Free worldwide weather service with no API key required
Alarm & Notification System
- Configurable Thresholds: User-defined limits for temperature, voltage, and current
- Latching Options: Choice between momentary and persistent alarm states
- Buzzer/Relay Output: 5V output drives up to 500mA for external devices
- Console Messaging: Real-time system messages with throttled warnings
Over-The-Air (OTA) Updates
Secure Update System
- Cryptographic Verification: RSA-4096 signature validation for firmware authenticity
- Streaming Installation: Memory-efficient TAR package extraction
- Atomic Updates: Complete verification before installation
- Rollback Protection: Automatic recovery if update fails
Recovery Systems
- Factory Partition: Brick-proof recovery accessible via GPIO pin
- Multiple Recovery Modes: GPIO pins provide different recovery options
- Automatic Restart: Scheduled 2-hour restarts for memory management
Hardware Specifications
System Compatibility
- Wide Input Range: 4.2V - 65V (supports 12V, 24V, 48V systems)
- Field Control: 0-15A field current, PWM frequencies 50Hz - 25kHz
- Current Measurement: ±500A capability with external shunt
- Temperature Range: -40°C to +85°C operating temperature
Power Consumption
- Ultra-Low Quiescent: 88µA @ 12V during normal operation
- Sleep Mode: 26µA @ 12V with ESP32 in deep sleep
- USB Programming: Alternative power source for development
Connectivity
- USB-C Programming: Native ESP32-S3 USB with no converter required
- Standard Connectors: Widely available RJ45 and other standard connectors
- Compact Design: Suitable for various marine installation locations
Development & Customization
- Full Source Code: Complete firmware and hardware designs available
- Arduino IDE Compatible: Standard development environment
- Extensive Documentation: Comprehensive technical documentation
- Community Support: Open platform for modifications and improvements
Configuration Options
- File-Based Settings: Human-readable configuration files
- Multiple Reset Types: Password, WiFi, and complete factory resets
- Debug Capabilities: Extensive logging and diagnostic capabilities
- Performance Monitoring: Real-time system health and timing analysis
Expandability
- Cloud Database Preparation: Framework for Supabase integration
- Community Features: Potential for fleet data sharing and optimization
- Platform Ecosystem: Integration with future X Engineering products
- Machine Learning: Foundation for advanced optimization algorithms