Equipment Telematics

Equipment Telematics

Overview

Integrate telematics data from heavy construction equipment (excavators, cranes, loaders, trucks) to monitor utilization, track location, analyze fuel efficiency, predict maintenance needs, and ensure safe operation.

Telematics Data Flow

┌─────────────────────────────────────────────────────────────────┐
│                  EQUIPMENT TELEMATICS                            │
├─────────────────────────────────────────────────────────────────┤
│                                                                  │
│  EQUIPMENT                  TELEMATICS              ANALYTICS   │
│  ─────────                  ──────────              ─────────   │
│                                                                  │
│  🚜 Excavator  ────┐       📍 Location              📊 Utilization│
│  🏗️ Crane      ────┼──────→ 🔧 Engine Hours ────────→ ⛽ Fuel      │
│  🚛 Truck      ────┤       ⛽ Fuel Level             🔧 Maintenance│
│  🚧 Loader     ────┘       ⚡ Performance            👷 Operator   │
│                                                                  │
│  METRICS TRACKED:                                               │
│  • GPS location and geofencing                                  │
│  • Engine hours and idle time                                   │
│  • Fuel consumption rate                                        │
│  • Load cycles and productivity                                 │
│  • Fault codes and diagnostics                                  │
│  • Operator behavior and safety                                 │
│                                                                  │
└─────────────────────────────────────────────────────────────────┘

Technical Implementation

from dataclasses import dataclass, field
from typing import List, Dict, Optional, Tuple
from datetime import datetime, timedelta
from enum import Enum
import statistics
import math

class EquipmentType(Enum):
    EXCAVATOR = "excavator"
    CRANE = "crane"
    LOADER = "loader"
    BULLDOZER = "bulldozer"
    DUMP_TRUCK = "dump_truck"
    CONCRETE_MIXER = "concrete_mixer"
    FORKLIFT = "forklift"
    COMPACTOR = "compactor"
    GRADER = "grader"
    TELEHANDLER = "telehandler"

class OperatingStatus(Enum):
    OPERATING = "operating"
    IDLE = "idle"
    OFF = "off"
    MAINTENANCE = "maintenance"
    FAULT = "fault"

class FaultSeverity(Enum):
    INFO = "info"
    WARNING = "warning"
    CRITICAL = "critical"
    SHUTDOWN = "shutdown"

@dataclass
class GPSLocation:
    latitude: float
    longitude: float
    altitude: float = 0.0
    speed: float = 0.0
    heading: float = 0.0
    timestamp: datetime = field(default_factory=datetime.now)

@dataclass
class TelematicsReading:
    equipment_id: str
    timestamp: datetime
    location: GPSLocation
    engine_hours: float
    fuel_level: float  # Percentage
    fuel_rate: float   # L/hr
    engine_rpm: int
    hydraulic_temp: float
    coolant_temp: float
    operating_status: OperatingStatus
    load_percentage: float = 0.0
    operator_id: str = ""

@dataclass
class FaultCode:
    code: str
    description: str
    severity: FaultSeverity
    timestamp: datetime
    equipment_id: str
    resolved: bool = False

@dataclass
class Equipment:
    id: str
    name: str
    equipment_type: EquipmentType
    make: str
    model: str
    year: int
    serial_number: str
    hourly_rate: float = 0.0
    fuel_capacity: float = 0.0  # Liters
    current_hours: float = 0.0
    next_service_hours: float = 0.0
    assigned_site: str = ""
    assigned_operator: str = ""

@dataclass
class Geofence:
    id: str
    name: str
    center_lat: float
    center_lon: float
    radius_meters: float
    allowed_equipment: List[str] = field(default_factory=list)

@dataclass
class UtilizationReport:
    equipment_id: str
    period_start: datetime
    period_end: datetime
    total_hours: float
    operating_hours: float
    idle_hours: float
    off_hours: float
    utilization_pct: float
    idle_pct: float
    fuel_consumed: float
    fuel_efficiency: float  # L/operating hour
    cycles: int

class EquipmentTelematics:
    """Integrate and analyze equipment telematics data."""

    # Maintenance intervals by type (hours)
    SERVICE_INTERVALS = {
        EquipmentType.EXCAVATOR: 250,
        EquipmentType.CRANE: 200,
        EquipmentType.LOADER: 250,
        EquipmentType.BULLDOZER: 250,
        EquipmentType.DUMP_TRUCK: 300,
    }

    # Typical fuel rates (L/hr)
    TYPICAL_FUEL_RATES = {
        EquipmentType.EXCAVATOR: 15,
        EquipmentType.CRANE: 12,
        EquipmentType.LOADER: 18,
        EquipmentType.BULLDOZER: 25,
        EquipmentType.DUMP_TRUCK: 20,
    }

    def __init__(self, fleet_name: str):
        self.fleet_name = fleet_name
        self.equipment: Dict[str, Equipment] = {}
        self.readings: List[TelematicsReading] = []
        self.faults: List[FaultCode] = []
        self.geofences: Dict[str, Geofence] = {}

    def register_equipment(self, id: str, name: str, equipment_type: EquipmentType,
                          make: str, model: str, year: int, serial_number: str,
                          hourly_rate: float = 0, fuel_capacity: float = 0) -> Equipment:
        """Register equipment in fleet."""
        equipment = Equipment(
            id=id,
            name=name,
            equipment_type=equipment_type,
            make=make,
            model=model,
            year=year,
            serial_number=serial_number,
            hourly_rate=hourly_rate,
            fuel_capacity=fuel_capacity
        )
        self.equipment[id] = equipment
        return equipment

    def add_geofence(self, id: str, name: str, center_lat: float,
                    center_lon: float, radius_meters: float,
                    allowed_equipment: List[str] = None) -> Geofence:
        """Add geofence boundary."""
        geofence = Geofence(
            id=id,
            name=name,
            center_lat=center_lat,
            center_lon=center_lon,
            radius_meters=radius_meters,
            allowed_equipment=allowed_equipment or []
        )
        self.geofences[id] = geofence
        return geofence

    def ingest_reading(self, equipment_id: str, location: GPSLocation,
                      engine_hours: float, fuel_level: float, fuel_rate: float,
                      engine_rpm: int, hydraulic_temp: float, coolant_temp: float,
                      load_percentage: float = 0, operator_id: str = "") -> TelematicsReading:
        """Ingest telematics reading from equipment."""
        if equipment_id not in self.equipment:
            raise ValueError(f"Unknown equipment: {equipment_id}")

        # Determine operating status
        if engine_rpm == 0:
            status = OperatingStatus.OFF
        elif engine_rpm < 800 or load_percentage < 10:
            status = OperatingStatus.IDLE
        else:
            status = OperatingStatus.OPERATING

        reading = TelematicsReading(
            equipment_id=equipment_id,
            timestamp=location.timestamp,
            location=location,
            engine_hours=engine_hours,
            fuel_level=fuel_level,
            fuel_rate=fuel_rate,
            engine_rpm=engine_rpm,
            hydraulic_temp=hydraulic_temp,
            coolant_temp=coolant_temp,
            operating_status=status,
            load_percentage=load_percentage,
            operator_id=operator_id
        )

        self.readings.append(reading)

        # Update equipment status
        equip = self.equipment[equipment_id]
        equip.current_hours = engine_hours

        # Check for issues
        self._check_diagnostics(equipment_id, reading)
        self._check_geofence(equipment_id, location)

        return reading

    def _check_diagnostics(self, equipment_id: str, reading: TelematicsReading):
        """Check for diagnostic issues."""
        equip = self.equipment[equipment_id]

        # High temperature warning
        if reading.hydraulic_temp > 90:
            self._add_fault(equipment_id, "HYD_TEMP_HIGH",
                          "Hydraulic temperature high", FaultSeverity.WARNING)

        if reading.coolant_temp > 100:
            self._add_fault(equipment_id, "COOLANT_TEMP_HIGH",
                          "Coolant temperature critical", FaultSeverity.CRITICAL)

        # Low fuel warning
        if reading.fuel_level < 15:
            self._add_fault(equipment_id, "FUEL_LOW",
                          "Fuel level below 15%", FaultSeverity.WARNING)

        # Service due
        service_interval = self.SERVICE_INTERVALS.get(equip.equipment_type, 250)
        hours_to_service = equip.next_service_hours - reading.engine_hours

        if hours_to_service < 0:
            self._add_fault(equipment_id, "SERVICE_OVERDUE",
                          "Maintenance service overdue", FaultSeverity.WARNING)
        elif hours_to_service < 50:
            self._add_fault(equipment_id, "SERVICE_DUE",
                          f"Service due in {hours_to_service:.0f} hours", FaultSeverity.INFO)

    def _check_geofence(self, equipment_id: str, location: GPSLocation):
        """Check geofence violations."""
        for geofence in self.geofences.values():
            # Calculate distance from center
            distance = self._haversine_distance(
                location.latitude, location.longitude,
                geofence.center_lat, geofence.center_lon
            )

            if distance > geofence.radius_meters:
                if (not geofence.allowed_equipment or
                    equipment_id in geofence.allowed_equipment):
                    self._add_fault(equipment_id, "GEOFENCE_EXIT",
                                  f"Equipment left {geofence.name} boundary",
                                  FaultSeverity.WARNING)

    def _haversine_distance(self, lat1: float, lon1: float,
                           lat2: float, lon2: float) -> float:
        """Calculate distance between two coordinates in meters."""
        R = 6371000  # Earth radius in meters

        phi1 = math.radians(lat1)
        phi2 = math.radians(lat2)
        delta_phi = math.radians(lat2 - lat1)
        delta_lambda = math.radians(lon2 - lon1)

        a = (math.sin(delta_phi/2)**2 +
             math.cos(phi1) * math.cos(phi2) * math.sin(delta_lambda/2)**2)
        c = 2 * math.atan2(math.sqrt(a), math.sqrt(1-a))

        return R * c

    def _add_fault(self, equipment_id: str, code: str,
                  description: str, severity: FaultSeverity):
        """Add fault code."""
        # Check if same fault already active
        existing = [f for f in self.faults
                   if f.equipment_id == equipment_id
                   and f.code == code
                   and not f.resolved]
        if existing:
            return

        fault = FaultCode(
            code=code,
            description=description,
            severity=severity,
            timestamp=datetime.now(),
            equipment_id=equipment_id
        )
        self.faults.append(fault)

    def get_current_status(self, equipment_id: str) -> Dict:
        """Get current status of equipment."""
        if equipment_id not in self.equipment:
            raise ValueError(f"Unknown equipment: {equipment_id}")

        equip = self.equipment[equipment_id]

        # Get latest reading
        readings = [r for r in self.readings if r.equipment_id == equipment_id]
        if not readings:
            return {"equipment": equip, "status": "no_data"}

        latest = max(readings, key=lambda r: r.timestamp)

        # Active faults
        active_faults = [f for f in self.faults
                        if f.equipment_id == equipment_id and not f.resolved]

        return {
            "equipment_id": equip.id,
            "name": equip.name,
            "type": equip.equipment_type.value,
            "status": latest.operating_status.value,
            "location": {
                "lat": latest.location.latitude,
                "lon": latest.location.longitude,
                "speed": latest.location.speed
            },
            "engine_hours": latest.engine_hours,
            "fuel_level": latest.fuel_level,
            "fuel_rate": latest.fuel_rate,
            "temps": {
                "hydraulic": latest.hydraulic_temp,
                "coolant": latest.coolant_temp
            },
            "operator": latest.operator_id,
            "active_faults": len(active_faults),
            "last_update": latest.timestamp
        }

    def calculate_utilization(self, equipment_id: str,
                             start_date: datetime,
                             end_date: datetime) -> UtilizationReport:
        """Calculate utilization metrics for equipment."""
        readings = [r for r in self.readings
                   if r.equipment_id == equipment_id
                   and start_date <= r.timestamp <= end_date]

        if not readings:
            return None

        readings.sort(key=lambda r: r.timestamp)

        total_hours = (end_date - start_date).total_seconds() / 3600
        operating_hours = 0
        idle_hours = 0
        fuel_consumed = 0

        # Calculate from readings
        for i in range(1, len(readings)):
            prev = readings[i-1]
            curr = readings[i]

            interval_hours = (curr.timestamp - prev.timestamp).total_seconds() / 3600

            if prev.operating_status == OperatingStatus.OPERATING:
                operating_hours += interval_hours
                fuel_consumed += prev.fuel_rate * interval_hours
            elif prev.operating_status == OperatingStatus.IDLE:
                idle_hours += interval_hours
                fuel_consumed += prev.fuel_rate * interval_hours * 0.3  # Idle uses ~30% fuel

        off_hours = total_hours - operating_hours - idle_hours
        utilization_pct = (operating_hours / total_hours * 100) if total_hours > 0 else 0
        idle_pct = (idle_hours / (operating_hours + idle_hours) * 100) if (operating_hours + idle_hours) > 0 else 0
        fuel_efficiency = (fuel_consumed / operating_hours) if operating_hours > 0 else 0

        return UtilizationReport(
            equipment_id=equipment_id,
            period_start=start_date,
            period_end=end_date,
            total_hours=total_hours,
            operating_hours=operating_hours,
            idle_hours=idle_hours,
            off_hours=off_hours,
            utilization_pct=utilization_pct,
            idle_pct=idle_pct,
            fuel_consumed=fuel_consumed,
            fuel_efficiency=fuel_efficiency,
            cycles=0  # Would need load cycle detection
        )

    def get_fleet_summary(self) -> Dict:
        """Get summary of entire fleet."""
        summary = {
            "total_equipment": len(self.equipment),
            "by_status": {},
            "by_type": {},
            "active_faults": 0,
            "service_due": []
        }

        for equip in self.equipment.values():
            # Count by type
            eq_type = equip.equipment_type.value
            summary["by_type"][eq_type] = summary["by_type"].get(eq_type, 0) + 1

            # Get current status
            try:
                status = self.get_current_status(equip.id)
                op_status = status.get("status", "unknown")
                summary["by_status"][op_status] = summary["by_status"].get(op_status, 0) + 1

                # Check service due
                service_interval = self.SERVICE_INTERVALS.get(equip.equipment_type, 250)
                hours_to_service = equip.next_service_hours - equip.current_hours
                if hours_to_service < 50:
                    summary["service_due"].append({
                        "equipment": equip.name,
                        "hours_remaining": hours_to_service
                    })
            except Exception:
                summary["by_status"]["unknown"] = summary["by_status"].get("unknown", 0) + 1

        # Count active faults
        summary["active_faults"] = len([f for f in self.faults if not f.resolved])

        return summary

    def predict_maintenance(self, equipment_id: str) -> Dict:
        """Predict maintenance needs based on usage patterns."""
        if equipment_id not in self.equipment:
            raise ValueError(f"Unknown equipment: {equipment_id}")

        equip = self.equipment[equipment_id]

        # Calculate average daily hours
        week_ago = datetime.now() - timedelta(days=7)
        recent_readings = [r for r in self.readings
                         if r.equipment_id == equipment_id
                         and r.timestamp > week_ago]

        if len(recent_readings) < 2:
            return {"prediction": "insufficient_data"}

        hours_start = min(r.engine_hours for r in recent_readings)
        hours_end = max(r.engine_hours for r in recent_readings)
        days = (max(r.timestamp for r in recent_readings) -
                min(r.timestamp for r in recent_readings)).days or 1

        daily_hours = (hours_end - hours_start) / days

        # Predict service date
        service_interval = self.SERVICE_INTERVALS.get(equip.equipment_type, 250)
        hours_to_service = equip.next_service_hours - equip.current_hours

        if daily_hours > 0:
            days_to_service = hours_to_service / daily_hours
            service_date = datetime.now() + timedelta(days=days_to_service)
        else:
            service_date = None

        return {
            "equipment_id": equipment_id,
            "current_hours": equip.current_hours,
            "next_service_hours": equip.next_service_hours,
            "hours_to_service": hours_to_service,
            "avg_daily_hours": daily_hours,
            "predicted_service_date": service_date,
            "service_type": "Routine maintenance",
            "estimated_downtime_hours": 8
        }

    def generate_report(self) -> str:
        """Generate fleet telematics report."""
        summary = self.get_fleet_summary()

        lines = [
            "# Equipment Telematics Report",
            "",
            f"**Fleet:** {self.fleet_name}",
            f"**Report Date:** {datetime.now().strftime('%Y-%m-%d %H:%M')}",
            "",
            "## Fleet Summary",
            "",
            f"| Metric | Value |",
            f"|--------|-------|",
            f"| Total Equipment | {summary['total_equipment']} |",
            f"| Active Faults | {summary['active_faults']} |",
            f"| Service Due | {len(summary['service_due'])} |",
            "",
            "## Status Distribution",
            ""
        ]

        for status, count in summary["by_status"].items():
            lines.append(f"- {status}: {count}")

        # Equipment details
        lines.extend([
            "",
            "## Equipment Status",
            "",
            "| Equipment | Type | Status | Hours | Fuel | Faults |",
            "|-----------|------|--------|-------|------|--------|"
        ])

        for equip in self.equipment.values():
            try:
                status = self.get_current_status(equip.id)
                status_icon = "✅" if status['status'] == 'operating' else "⏸️" if status['status'] == 'idle' else "⏹️"
                lines.append(
                    f"| {equip.name} | {equip.equipment_type.value} | "
                    f"{status_icon} {status['status']} | {status['engine_hours']:.0f} | "
                    f"{status['fuel_level']:.0f}% | {status['active_faults']} |"
                )
            except Exception:
                lines.append(
                    f"| {equip.name} | {equip.equipment_type.value} | ⚠️ No data | - | - | - |"
                )

        # Service due
        if summary["service_due"]:
            lines.extend([
                "",
                "## Service Due Soon",
                "",
                "| Equipment | Hours Remaining |",
                "|-----------|-----------------|"
            ])
            for svc in summary["service_due"]:
                lines.append(f"| {svc['equipment']} | {svc['hours_remaining']:.0f} |")

        # Active faults
        active_faults = [f for f in self.faults if not f.resolved]
        if active_faults:
            lines.extend([
                "",
                "## Active Faults",
                "",
                "| Equipment | Code | Description | Severity |",
                "|-----------|------|-------------|----------|"
            ])
            for fault in active_faults[:10]:
                sev_icon = "🔴" if fault.severity == FaultSeverity.CRITICAL else "🟡"
                equip = self.equipment.get(fault.equipment_id)
                lines.append(
                    f"| {equip.name if equip else fault.equipment_id} | "
                    f"{fault.code} | {fault.description} | {sev_icon} {fault.severity.value} |"
                )

        return "\n".join(lines)

Quick Start

from datetime import datetime, timedelta

# Initialize telematics system
telematics = EquipmentTelematics("Site A Fleet")

# Register equipment
telematics.register_equipment(
    "EX-001", "Excavator #1", EquipmentType.EXCAVATOR,
    make="Caterpillar", model="320", year=2022,
    serial_number="CAT320X12345",
    hourly_rate=150, fuel_capacity=400
)

telematics.register_equipment(
    "CR-001", "Tower Crane #1", EquipmentType.CRANE,
    make="Liebherr", model="200EC-H", year=2021,
    serial_number="LH200EC54321",
    hourly_rate=200, fuel_capacity=300
)

# Add geofence for site boundary
telematics.add_geofence(
    "SITE-A", "Site A Boundary",
    center_lat=40.7128, center_lon=-74.0060,
    radius_meters=500
)

# Ingest telematics reading
location = GPSLocation(
    latitude=40.7128, longitude=-74.0059,
    speed=5.0, timestamp=datetime.now()
)

telematics.ingest_reading(
    "EX-001", location,
    engine_hours=1250.5,
    fuel_level=65.0,
    fuel_rate=18.5,
    engine_rpm=1800,
    hydraulic_temp=75.0,
    coolant_temp=85.0,
    load_percentage=75,
    operator_id="OP-101"
)

# Get current status
status = telematics.get_current_status("EX-001")
print(f"Excavator status: {status['status']}")
print(f"Location: {status['location']}")
print(f"Fuel: {status['fuel_level']}%")

# Calculate utilization
util = telematics.calculate_utilization(
    "EX-001",
    datetime.now() - timedelta(days=7),
    datetime.now()
)
if util:
    print(f"Utilization: {util.utilization_pct:.1f}%")
    print(f"Fuel efficiency: {util.fuel_efficiency:.1f} L/hr")

# Predict maintenance
maintenance = telematics.predict_maintenance("EX-001")
print(f"Days to service: {maintenance.get('predicted_service_date')}")

# Fleet summary
summary = telematics.get_fleet_summary()
print(f"Fleet: {summary['total_equipment']} units")

# Generate report
print(telematics.generate_report())

Requirements

pip install (no external dependencies)