Solar Charge & BTS Monitoring System
Enterprise-grade real-time monitoring platform for solar power installations and telecommunications base stations with comprehensive battery management, power analytics, and remote configuration using industrial protocols.
Project Overview
The Solar Charge & BTS Monitoring System (RDDSPM) is a comprehensive enterprise solution designed to monitor and manage solar power installations and telecommunications base station infrastructure in real-time. This system integrates hardware sensors, data acquisition, and web-based visualization to provide complete visibility into power systems, battery health, and operational metrics.
The system was developed to address the critical need for continuous monitoring of telecommunications infrastructure powered by solar energy, enabling operators to ensure uptime, prevent equipment failure, and optimize energy usage across multiple remote sites.
Key Features
Battery Management System (BMS) Monitoring
Real-time monitoring of battery parameters including voltage, current, temperature, state of charge (SOC), and cell balancing status. Critical for preventing battery failure and extending lifespan in solar-powered installations.
Solar Charge Controller (SCC) Tracking
Monitor solar panel voltage, current, power output, charging status, and maximum power point tracking (MPPT) efficiency to optimize solar energy harvesting throughout the day.
Rectifier & Power Distribution
Track AC/DC power conversion, load distribution, backup power status, and energy consumption patterns for complete power system visibility and optimization.
Digital I/O Control
Remote monitoring and control of digital inputs/outputs for alarms, relays, and auxiliary equipment with configurable thresholds and automation rules.
Data Logging & Analytics
Historical data storage with time-series analysis, trend visualization, and Excel/CSV export capabilities for maintenance planning and performance optimization.
Multi-Site Management
Support for multiple installation sites with site-specific configurations, network settings, and customizable parameters for each BTS location.
Technical Implementation
The system follows a three-tier architecture combining industrial IoT protocols with modern web technologies:
Backend Architecture
Built with CodeIgniter 4 framework using MVC architecture. MySQL database stores configuration, monitoring data, and historical logs. RESTful API design enables AJAX-based real-time updates with session-based authentication and role-based access control.
Data Acquisition Layer
Node-RED provides visual programming for Modbus communication and data flow automation. Industrial-standard Modbus protocol reads sensor data from hardware devices with automated polling and database synchronization.
Frontend & Visualization
Responsive multi-page dashboard interface with AJAX real-time updates without page reload. Data export functionality using Box/Spout library for Excel/CSV report generation and web-based configuration panels for remote system settings.
System Architecture
The monitoring system integrates three distinct layers:
1. Hardware Layer
Physical sensors, charge controllers, BMS units, and I/O modules connected via Modbus RTU/TCP protocols
2. Data Acquisition Layer
Node-RED flows for protocol conversion, data normalization, error handling, and database insertion
3. Application Layer
CodeIgniter web application providing visualization, user management, reporting, and remote configuration
Results & Impact
- ✓ 24/7 Monitoring: Continuous real-time visibility into critical power infrastructure
- ✓ Preventive Maintenance: Early warning system for battery degradation and equipment issues
- ✓ Energy Optimization: Data-driven insights for improving solar harvesting efficiency
- ✓ Remote Management: Reduced site visits through web-based configuration and control
- ✓ Compliance & Reporting: Automated data logging for maintenance records and regulatory compliance
Technologies Used
Backend
Frontend
IoT & Automation
Libraries
Challenges & Solutions
Challenge: Integrating multiple industrial hardware devices with different Modbus implementations.
Solution: Used Node-RED's flexible Modbus nodes with custom parsing logic for each device type, implementing proper error handling and timeout management.
Challenge: Balancing real-time dashboard responsiveness with server load from frequent AJAX polling.
Solution: Implemented efficient polling strategies with configurable intervals and database indexing to maintain performance under continuous load.
Challenge: Managing historical data storage for long-term monitoring without database bloat.
Solution: Created data archival strategies with proper indexing and implemented data aggregation for older records while maintaining detailed recent history.
Security Considerations
Authentication
Session-based with secure password storage
CSRF Protection
On all form submissions
SQL Injection
Query builder & prepared statements
XSS Protection
Automatic output escaping
Access Control
Role-based for sensitive operations
Configuration
Environment-based security settings
Interested in IoT Monitoring Solutions?
Let's discuss how we can build monitoring solutions for your infrastructure needs.