https://github.com/dmartingarcia/kubota-smart-tractor
🔋 ESP8266-based system to automatically manage tractor battery charging. Prevents overcharging via voltage monitoring (14.0V-14.8V hysteresis), with WiFi/OTA updates and fail-safe relay control. Perfect for agricultural IoT! 🚜⚡
https://github.com/dmartingarcia/kubota-smart-tractor
arduino battery-management-system esp8266 platformio
Last synced: about 1 month ago
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🔋 ESP8266-based system to automatically manage tractor battery charging. Prevents overcharging via voltage monitoring (14.0V-14.8V hysteresis), with WiFi/OTA updates and fail-safe relay control. Perfect for agricultural IoT! 🚜⚡
- Host: GitHub
- URL: https://github.com/dmartingarcia/kubota-smart-tractor
- Owner: dmartingarcia
- Created: 2024-08-21T23:32:03.000Z (9 months ago)
- Default Branch: main
- Last Pushed: 2025-04-04T04:43:23.000Z (about 2 months ago)
- Last Synced: 2025-04-04T05:19:32.739Z (about 2 months ago)
- Topics: arduino, battery-management-system, esp8266, platformio
- Language: C++
- Homepage:
- Size: 22.5 KB
- Stars: 0
- Watchers: 1
- Forks: 0
- Open Issues: 0
-
Metadata Files:
- Readme: README.md
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README
# Smart Tractor Alternator Controller 🚜⚡
[](https://opensource.org/licenses/MIT)
ESP8266-based intelligent charging system with adaptive PID control and web monitoring. Maintains optimal battery health using advanced charge management.
## Features ✨
- 🎮 **Adaptive PID Control** - Maintains precise voltage regulation
- ⚡ **Dual Output Modes** - Relay or PWM MOSFET control (configurable)
- 📶 **WiFi Web Interface** - Real-time monitoring & historical charts
- 🔄 **OTA Updates** - Wireless firmware upgrades
- 📊 **Advanced Telemetry** - Voltage, PWM%, PID output, and engine status
- 🔒 **Multi-layer Protection** - Over-voltage cutoff, rate limiting, and thermal safety
## Hardware Requirements 🔨
| Component | Specification |
|------------------------|-----------------------------------------|
| Microcontroller | ESP8266 (NodeMCU/Wemos D1 Mini) |
| Voltage Divider | R1=220kΩ, R2=68kΩ (1% tolerance) |
| Output Device | 5V SPDT Relay **or** 30A MOSFET + Heatsink |
| Power Input | 12V Tractor Battery |
| Protection | 10A Fuse, Reverse Polarity Diode |
**Wiring Diagrams:**
*Relay Mode:*
Battery+ → Fuse → [220k] → A0 → [68k] → GND
Relay COM → Alternator Field Circuit
*MOSFET Mode:*
Battery+ → MOSFET Source → Alternator Field
MOSFET Gate → PWM Pin (D1)
MOSFET Drain → GND (with heatsink)
## Installation 📥
### PlatformIO Setup
1. Install [PlatformIO Core](https://platformio.org/install)
2. Clone repository:
```bash
git clone https://github.com/yourrepo/smart-tractor-charger.git
cd smart-tractor-charger
```
3. Install dependencies:
```bash
pio pkg install
```
### Configuration
1. Create `include/secrets.h`:
```cpp
const char* ssid = "YOUR_SSID";
const char* password = "YOUR_PASSWORD";
```
2. Configure operation mode in `src/main.cpp`:
```cpp
#define USE_PWM true // false for relay mode
#define OUTPUT_PIN D1 // PWM-capable pin
#define PID_SETPOINT 14.6 // Optimal charging voltage
```
## Calibration Guide 🔧
### Voltage Calibration
1. Connect known good battery (12.6V+)
2. Measure actual voltage (V_true) with multimeter
3. Update calibration constants:
```cpp
#define CALIBRATION_IN_VOLTAGE 12.65 // Measured voltage
#define CALIBRATION_A0_VOLTAGE 2.89 // Serial monitor reading
```
### PID Tuning Procedure
1. **Initial Setup** (P-only control):
```cpp
PID chargePID(&pidInput, &pidOutput, &pidSetpoint, 80.0, 0, 0, DIRECT);
```
2. **Tuning Steps**:
- Increase P until system oscillates, then reduce by 50%
- Add Integral control (start with 0.1*P)
- Add Derivative control (start with 0.01*P)
3. **Example Safe Values**:
```cpp
PID chargePID(&pidInput, &pidOutput, &pidSetpoint, 80.0, 5.0, 0.5, DIRECT);
```
## Web Interface 🌐
Access via `http://smarttractor.local` or device IP:
**Features:**
- Real-time voltage graph (60s history)
- PID output visualization
- PWM %/Relay status indicator
- Engine running detection status
- System mode (PWM/Relay) display
## System Indicators 💡
| LED Pattern | System State |
|------------------------|----------------------------|
| Slow Blink (0.2Hz) | Alternator OFF |
| Rapid Blink (1Hz) | PWM Active |
| Solid ON (2Hz) | Relay Active |
| Double Flash (0.5Hz) | WiFi Connection Failed |
## OTA Updates 🛠️
1. Connect to device WiFi
2. In PlatformIO:
```bash
pio run --target upload --upload-port smarttractor.local
```
3. Monitor serial output for progress
## Troubleshooting 🔍
| Issue | Solution |
|------------------------|-------------------------------|
| No PWM output | Verify MOSFET wiring & PWM config |
| Voltage oscillations | Reduce PID P value |
| Web interface offline | Check mDNS & server.begin() |
| Overheating MOSFET | Add heatsink & verify current |
## Safety Systems ⚠️
- **Multi-stage Protection**:
- Hard-cutoff at 15.0V (absolute maximum)
- PWM rate limiting (max 10%/s change)
- Thermal shutdown (requires temp sensor)
- Watchdog timer (auto-reset on lockup)
**Critical Notes**:
- 🔥 Always use appropriately rated components
- 🛑 Double-check polarity before power-on
- 🔋 Maintain battery temperature monitoring
- 🧯 Enclose in IP67-rated waterproof case
## License 📄
MIT License - See [LICENSE](LICENSE) for details
*PID Library:* BSD 3-Clause (included in dependencies)