Charging Cycles for Assets with IoT Trackers

Why Charging Cycles Matter

Batteries are one of the most expensive components in machines. Wrong charging behaviour reduces battery lifespan and increases costs. By monitoring charging cycles, you gain insights into how your machines are used and maintained.

Requirements

• An ToolSense IoT tracker that measures battery voltage 24/7 (e.g. Blackbird tracker).

• The nominal voltage level of the machine’s battery (e.g. 24V, 36V, 48V).

Setup in ToolSense

1. Go to the asset type of the machine in ToolSense.

   

2. Enter the battery voltage level (e.g. 24V).
   

   

How ToolSense Calculates Charging Cycles

ToolSense detects changes in battery voltage to estimate charging cycles:

Every nominal voltage group has a predefined charging voltage, which goes the following way:

Charging is detected, whenever the external power measured by the tracker is equal or greater than the charging voltage.

Based on these patterns, ToolSense automatically estimates the number of charging cycles.

Benefits

• Monitor battery lifespan.

• Reduce replacement costs.

• Gain operational insights into charging behavior.

Please note that in order for this feature to work, the trackers need direct connection to the battery. If the external power gets cut off in any way, charging cycles will not be detected.