IoT Fleet GPS Tracking System — Real-Time Vehicle Monitoring & AI Route Optimization
A 4G GPS tracking platform for a 300-vehicle logistics fleet — 5-second live location, AI route optimization, driver behavior scoring, and automated compliance reports — cutting fuel costs by 18%.
⚠The Problem
A logistics company operating 300 vehicles across Pakistan had no real-time visibility into fleet location. Drivers self-reported fuel consumption — actual vs. reported discrepancies reached 20%. Unauthorized route deviations were costing extra fuel and creating liability. Regulatory compliance logs (driver hours, route documentation) were prepared manually, taking 3 days per month per vehicle.
💡Our Solution
We designed a plug-in OBD-II telematics device (no wiring) using ESP32 with a SIM7600 4G module. The device publishes GPS coordinates every 5 seconds and CAN bus data (actual fuel consumption, RPM, odometer) every 30 seconds to a Node.js MQTT backend. PostgreSQL stores complete trip history. A Python service runs AI route optimization using OpenStreetMap data and historical traffic patterns, reducing per-trip distance by 8% on average. A driver behavior engine scores acceleration, braking, cornering, and speeding events, feeding a weekly driver scorecard. Automated compliance reports are generated and emailed every Monday morning.
🔗System Architecture
OBD-II Device (ESP32+4G) → MQTT → Node.js Backend → PostgreSQL + Redis → React Dashboard + Flutter Driver AppTech Stack
- Custom OBD-II telematics device (ESP32 + SIM7600)
- u-blox GPS M8 module
- CAN bus reader (fuel, RPM, odometer)
- Accelerometer for harsh event detection
- Tamper-detect sensor
- 4G LTE (primary)
- MQTT to cloud
- SMS fallback for alerts
- Node.js MQTT backend
- PostgreSQL (trip history)
- Redis (live positions cache)
- Python AI routing service
- AWS SES (report emails)
- React dashboard with Mapbox live map
- Flutter driver app (route guidance)
- Automated PDF compliance reports
Key Features
Results Delivered
- 18% reduction in fuel costs via AI routing + behavior scoring
- 5-second live GPS accuracy across 300 vehicles
- Unauthorized route deviation incidents down 74%
- Compliance report generation reduced from 3 days to 0 (automated)
- Fuel discrepancy detection flagged 12% of driver reports as inaccurate
Technologies
Who This Is For
Logistics companies, delivery fleets, construction equipment operators, public transport authorities
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