Modern energy systems are shifting from the era of manual measurements to complete automation. For businesses, simply knowing that equipment is “running” is no longer sufficient. Owners require accurate, structured, and instantly available data to effectively manage facilities, evaluate ROI, and make informed decisions.
At VRG Soft, we accepted this challenge and created a unified digital platform that doesn’t just monitor, but aggregates, processes, and analyzes data from all energy system components: inverters, batteries, generators, PV strings, and the utility grid.
Here is how our solution’s architecture is built, why data processing precision is critical, and the technologies we used to achieve stability.
Architecture: Flexibility, Scalability, Real-Time
To ensure maximum flexibility and rapid development speed, we chose a three-tier architecture where each component is responsible for its own specific domain:
1. Data Collection Layer (Node-RED)
This is the low-level integration layer that communicates directly with the hardware.
- Functions: Polling inverters and generators via Modbus TCP, cycle control, Watchdog timers, and automatic restarts in case of anomalies.
- Result: All “raw” data is collected and passed downstream in JSON format, ensuring a continuous flow of information even during unstable connectivity.
2. Processing Core (Laravel Backend)
The “brain” of the system that transforms byte streams into business value.
- Functions: Parsing Modbus registers, performing complex mathematical conversions, applying normalization rules, writing to an optimized database structure, and generating events (PlantEvents).
- Integrations: REST API for the frontend and a Telegram notification system.
3. Visualization (Vue.js Frontend)
The interface that ensures transparency in real-time.
- Functions: Adaptive dashboards for specific sections and facilities, real-time charts, event logs, and a multi-language UI.
Depth of Integration: Working with Hardware
Our platform is not just a theoretical model, but a solution tested on real industrial equipment. We have implemented deep integration with:
- Deye Inverters (SUN-50K-SG01HP3-EU-BM4): We process 12 register ranges for each 50kW three-phase inverter. The system reads data regarding generation, MPPT tracker performance, Li-BMS status, and load.
- ComAp Generators (InteliLite 4 AMF25): Full control of diesel generators (100–150 kVA) – from fuel levels and RPM to active power and operating modes.
Intelligent Data Processing: How We Guarantee Accuracy
Every inverter has its own Modbus register map, and working with them requires meticulous precision. Simply “reading” the data is not enough – it must be interpreted correctly.
Our processing module performs:
- Combining 32-bit Values: Correctly merging High + Low words to obtain accurate large numbers.
- Physical Conversion: Transforming bytes into real physical units (W → kW, V → kV, A → kA).
- State Decoding: Deciphering error bitmasks (Modbus 553–558) to instantly identify issue types (Fault/Warning/Normal).
Validation System
We guarantee data reliability through multi-level verification:
- Filtering values that fall outside the physically possible ranges for a specific model.
- Screening out uninitialized values.
- Fallback processing logic to maintain historical data integrity.
Complete Energy Control for Business
Thanks to this deep technical foundation, the client receives Enterprise-grade analytics. The system provides a complete picture of energy flow:
PV → Inverter → Load → Grid → Generator
The platform allows tracking of:
- PV and Generation: Power output per string and MPPT, daily and total efficiency.
- Batteries: State of Charge (SOC), voltage, current, and charge/discharge cycles.
- Grid: Parameters by phase (L1/L2/L3), frequency, energy import and export.
- System Health: Temperatures, critical errors, and warnings in real-time.
Summary: Built for the Future
The energy platform from VRG Soft combines technical depth, high reliability, and convenient business functionality. We have created a product that allows for scaling to hundreds of devices, easy connection of new equipment models, and data integration with ERP/CRM systems.
We make energy systems transparent and businesses efficient. And this is just the beginning: ahead lies even more automation, intelligent scenarios, and advanced analytics.