Smarter batteries, powered by their own data
With Zenfinity’s Digital Twin Platform, every battery becomes a live data source — from first deployment to recycling. By understanding what’s happening inside each cell in real time, we can refine design, extend life, and unlock better performance for every customer.
Zenfinity Digital Twin
The brain behind every Zenfinity battery
From the moment a pack starts being manufactured in the factory, it begins generating a continuous stream of data: temperatures, currents, voltages, charge–discharge patterns, locations, and events in the field.
Our Digital Twin captures and learns from this data, creating a virtual replica of every battery system. This lets us:
- Design packs around real duty cycles, not lab guesses
- Continuously improve performance, safety, and lifetime
- Turn batteries from “black boxes” into transparent, manageable assets
Through data, we’re building more reliable, safer, and more sustainable battery systems for fleets, OEMs, and energy customers
Keep your batteries working, not waiting
Battery fleet management – maximizing uptime
A live view of your entire battery fleet — across vehicles, sites, or storage systems — helps operators act before a minor anomaly becomes a costly shutdown.
- Real-time monitoring of key parameters and alarms
- Pack- and site-level dashboards tailored to EV fleets and energy storage
- Insights that reduce unplanned downtime and keep assets earning
Remote diagnostics – fewer site visits, faster resolutions
Instead of sending specialists to inspect a pack, engineers can diagnose issues remotely using data from the Digital Twin.
- Drill down to cell, string, or module level from anywhere
- Faster troubleshooting and root-cause analysis
- Lower dependence on scarce on-ground battery experts
Anomaly detection – catching problems early
Machine-learning driven anomaly detection identifies unusual behavior long before it becomes a failure.
- Spot potential defects or misuse patterns early
- Contain field issues and reduce the risk of large-scale recalls
- Protect both brand trust and operating margins
Improve performance without touching the hardware
Over-the-air updates – performance at the speed of software
Battery behavior is heavily influenced by software — control algorithms, limits, protections. With Zenfinity:
- Deployed batteries receive over-the-air (OTA) firmware and configuration updates
- New learnings from the field can be rolled out fleet-wide in one go
- Packs get smarter and more efficient over time, without physical upgrades
One-click system checks – instant health snapshots
Operators can trigger a full self-test of a battery system from the dashboard.
- Automated test routines run in the background
- Detailed event logs and reports highlight what needs attention
- Shortens the time from issue to action
Seeing ageing before it shows up on the road
High-resolution telemetry – the foundation for better cells
Zenfinity’s Digital Twin captures rich telemetry at the cell and pack level.
- High-frequency data from real routes, climates, and loads
- Insights into how different chemistries behave in Indian conditions
- Feedback loop from field back to cell R&D and pack design
Predictive health models – planning replacements, not reacting to failures
By combining telemetry with advanced models, we can forecast how a pack will age.
- State-of-health estimation at cell and pack level
- Remaining useful life predictions for each asset
- Smarter decisions on rotation, refurbishment, or replacement
Enabling confident warranties & service models
When battery usage and health are clearly understood:
- Warranties can be structured around data-backed performance
- Service contracts and BaaS models become easier to price and manage
- Risk is reduced for both Zenfinity and our customers
Enterprise-grade protection for critical energy assets
Secure cloud infrastructure
Zenfinity’s Digital Twin is hosted on industry-standard, security-hardened cloud infrastructure, aligned with modern data protection and cyber security practices.
- Encrypted communication between batteries, gateways, and cloud
- Robust backup and disaster recovery mechanisms
- Auditable logs for compliance and investigations
Fine-grained access management
Different stakeholders need different levels of visibility.
- Role-based, multi-tenant access control
- Separate views for OEMs, fleet operators, service partners, and internal teams
- Strict permissioning so sensitive data only reaches the right eyes
From first life to second life to recycling
Full lifecycle visibility – from deployment to retirement
With Digital Twin data, we know how each battery has lived its life:
- Duty cycles, operating conditions, and stress events
- True health at the end of first life
- Suitability for second-life applications or direct recycling
Enabling buy-back & recycling programs
This transparency allows Zenfinity and its partners to:
- Structure buy-back offers tied to verified usage and health history
- Channel suitable packs into second-life stationary storage
- Route end-of-life batteries to responsible recyclers with full traceability
