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12:00 · 2.32 kW from the array
Battery 100 %
Load · 400 W
24 hours · array output, load, battery charge
57.7 °C inside · 35 °C outside
Heat exchanger · 136 W
Drop 0.60 m · stops within 54 mm
Isolators · fn 10.1 Hz
Vehicle floor · input vibration
Sensor · 6.6 W at the device
Camera · 26.4 W at the device
Access point · 52.8 W at the device
PTZ camera · 75.0 W at the device
PoE switch · 24 ports
227 N · at 15 m
3.40 kN·m · added at the base
Wind profile · 29.5 m/s at 3 m, 40.3 m/s at 27 m
Alternator · 60 A at 14 V
Load · 120 W
Battery 26 % · 12:00, parked
LFP battery and inverter
Intro.
Hardware & power · Explainer
Six engineering checks behind every field installation, each worked live: the solar and battery balance through a day and a night, the heat an enclosure can shed, the isolation that protects a transit rack, the Power over Ethernet budget, the wind on a mounted antenna and the power a crew truck carries. Every number below is computed live from your inputs.
01 · Microgrid energy balance
Daily irradiation outside the atmosphere follows from latitude and date: H₀ = (24 · 3600 · Gsc / π)(1 + 0.033 cos(360n/365))(cos φ cos δ sin ωs + ωs sin φ sin δ), with sunset hour angle ωs = arccos(−tan φ tan δ). The clearness index takes it to the ground, and the array delivers its rated kilowatts times that irradiation times a performance ratio of 0.8, shaped hour by hour by the Sun’s height. The battery carries the load through the dark on 90 % of its capacity.
Date
Sky
02 · Enclosure thermal
A free-standing painted steel enclosure loses heat through every face but its base, A = WD + 2H(W + D), at about 5.5 W/m²K, so the inside runs ΔT = P / (5.5 A) above ambient. A sealed IP66 / NEMA 4X box that runs too hot needs a closed-loop exchanger or air conditioner for the difference, P − 5.5 A (Tmax − Tamb). A filtered-fan IP54 box moves V = 3.1 (P − 5.5 A ΔT) / ΔT m³/h of outside air, and no fan can cool below ambient. Equipment here is held at 50 °C or less.
Enclosure, W × H × D
Protection
03 · Rugged rack isolation
The inner rack frame rides on eight elastomer isolators, a mass on a spring with natural frequency fn = (1/2π)√(k/m). Above √2 times fn the isolators cut vibration: transmissibility is √((1 + (2ζr)²) / ((1 − r²)² + (2ζr)²)) with r = f / fn and damping ζ = 0.1. In a drop the frame meets the case at v = √(2gh); the isolators stop it within v / ωn at a peak of v ωn / g. Softer isolators protect better and need more room to move.
04 · Power over Ethernet budget
A PoE switch reserves each port’s class power from its supply: 7 W for a class 2 sensor, 30 W for a class 4 camera, 60 W for a class 6 access point and 90 W for a class 8 pan-tilt camera with a heater. The cable burns I²R on the way: at 44 V and 20 Ω for 802.3af, 50 V and 12.5 Ω for 802.3at, and two pair-sets in parallel at 50 or 52 V for 802.3bt, scaled by length from 100 m. Ports are powered in order until the supply is spent; the rest stay dark.
Switch PoE supply
05 · Mounting and wind load
Wind speed rises with height by the power law v(h) = v₁₀ (h / 10)1/7 over open ground. The dynamic pressure is q = ½ρv² with ρ = 1.225 kg/m³, and the drag on the equipment is F = q Cd A, with Cd about 1.2 for a flat panel facing the wind and 1.4 for a solid dish without a radome or a sector antenna face-on. The force acts at the mount, so the bending moment it adds at the tower base is F · h.
Equipment
06 · Mobile power
A DC-DC charger draws the alternator’s spare current at 14 V into a lithium iron phosphate battery at 95 % efficiency; an inverter at 90 % efficiency runs the load around the clock. Charging power is 14 I × 0.95, the battery runs the load for 0.9 E η / P hours, and the day balances when the hours of driving put back what the load takes. The scene plays one day in 24 seconds, driving first.
The engineering checks behind every field installation, each worked live: the solar and battery balance through a day and a night, the heat an enclosure can shed, the isolation that protects a transit rack, the Power over Ethernet budget, the wind on a mounted antenna and the power a crew truck carries. Every number below is computed live from your inputs.
Daily irradiation outside the atmosphere follows from latitude and date: H₀ = (24 · 3600 · Gsc / π)(1 + 0.033 cos(360n/365))(cos φ cos δ sin ωs + ωs sin φ sin δ), with sunset hour angle ωs = arccos(−tan φ tan δ). The clearness index takes it to the ground, and the array delivers its rated kilowatts times that irradiation times a performance ratio of 0.8, shaped hour by hour by the Sun’s height. The battery carries the load through the dark on 90 % of its capacity.
A free-standing painted steel enclosure loses heat through every face but its base, A = WD + 2H(W + D), at about 5.5 W/m²K, so the inside runs ΔT = P / (5.5 A) above ambient. A sealed IP66 / NEMA 4X box that runs too hot needs a closed-loop exchanger or air conditioner for the difference, P − 5.5 A (Tmax − Tamb). A filtered-fan IP54 box moves V = 3.1 (P − 5.5 A ΔT) / ΔT m³/h of outside air, and no fan can cool below ambient. Equipment here is held at 50 °C or less.
The inner rack frame rides on eight elastomer isolators, a mass on a spring with natural frequency fn = (1/2π)√(k/m). Above √2 times fn the isolators cut vibration: transmissibility is √((1 + (2ζr)²) / ((1 − r²)² + (2ζr)²)) with r = f / fn and damping ζ = 0.1. In a drop the frame meets the case at v = √(2gh); the isolators stop it within v / ωn at a peak of v ωn / g. Softer isolators protect better and need more room to move.
A PoE switch reserves each port’s class power from its supply: 7 W for a class 2 sensor, 30 W for a class 4 camera, 60 W for a class 6 access point and 90 W for a class 8 pan-tilt camera with a heater. The cable burns I²R on the way: at 44 V and 20 Ω for 802.3af, 50 V and 12.5 Ω for 802.3at, and two pair-sets in parallel at 50 or 52 V for 802.3bt, scaled by length from 100 m. Ports are powered in order until the supply is spent; the rest stay dark.
Wind speed rises with height by the power law v(h) = v₁₀ (h / 10)1/7 over open ground. The dynamic pressure is q = ½ρv² with ρ = 1.225 kg/m³, and the drag on the equipment is F = q Cd A, with Cd about 1.2 for a flat panel facing the wind and 1.4 for a solid dish without a radome or a sector antenna face-on. The force acts at the mount, so the bending moment it adds at the tower base is F · h.
A DC-DC charger draws the alternator’s spare current at 14 V into a lithium iron phosphate battery at 95 % efficiency; an inverter at 90 % efficiency runs the load around the clock. Charging power is 14 I × 0.95, the battery runs the load for 0.9 E η / P hours, and the day balances when the hours of driving put back what the load takes. The scene plays one day in 24 seconds, driving first.
The base unit is one station: an enclosure with its power, compute and radio, rated for the environment it stands in. A site joins a few stations on shared power and a mast; a cluster shares a depot and a spares pool; a region standardises on one bill of materials; a global network repeats it. Environmental classes and ingress ratings let the same block be specified for a new climate without redesign.
Sources IEC 60721-3-4, Classification of environmental conditions: stationary use at non-weatherprotected locations; IEC 60529, Degrees of protection provided by enclosures (IP Code)
Before a design ships it passes a sequence of tests: cold, dry heat, damp heat, vibration and shock under the IEC 60068 methods; immunity and emissions under the IEC 61000 series; electrical safety under IEC 62368-1. A field pilot at a real site comes last. A unit that fails any gate goes back to design, and the test record travels with every station built to that design.
Sources IEC 60068-2 series, Environmental testing: tests; IEC 61000-6-2, Electromagnetic compatibility: immunity standard for industrial environments; IEC 62368-1, Audio/video, information and communication technology equipment: safety requirements
Storage is a stack of decisions. The cells set energy and temperature tolerance; the battery management system balances them and refuses to charge lithium cells below freezing, which plates the anode; thermal control keeps them in range; the enclosure contains a failure. Lithium batteries ship only after the United Nations transport tests, and industrial packs follow the IEC safety requirements for secondary lithium cells.
Sources United Nations, Manual of Tests and Criteria, Part III, sub-section 38.3; IEC 62619, Safety requirements for secondary lithium cells and batteries for use in industrial applications
A station is built from line-replaceable modules, so a visit is a swap and the repair happens at the bench. Availability is mean time between failures divided by that time plus the mean time to restore, so shortening the restore time pays as much as rarer faults. Spares are pooled at the depot and sized from failure rates and supplier lead times, not stocked at every site.
Sources O’Connor and Kleyner, Practical Reliability Engineering, 5th edition, Wiley; IEC 60050-192, International Electrotechnical Vocabulary: dependability
Hardware has its own lifecycle: commissioning against an acceptance test, years of operation, preventive maintenance, a mid-life refresh of batteries and compute, and retirement. At the end, electronics go to separate collection and treatment, and batteries carry obligations for collection, recycled content and information on their condition, so a decommissioned station becomes recovered material rather than waste.
Sources Directive 2012/19/EU on waste electrical and electronic equipment (WEEE); Regulation (EU) 2023/1542 concerning batteries and waste batteries
To which environmental class was it tested, and was the laboratory accredited for those tests? How long until a failed module is replaced, and where do the spares sit? What does the power system deliver on the shortest day? Can parts come from more than one maker? What is recovered at end of life? Accreditation of testing laboratories is what makes the answer on testing worth trusting.
Sources ISO/IEC 17025, General requirements for the competence of testing and calibration laboratories