Weatherizing AEI Systems Before Winter: The Field-Tech Procedure That Keeps Your Data Flowing

Prepare AEI systems for freezing weather with this field-proven winterisation procedure that keeps data flowing and equipment performing reliably from first frost to final thaw.

When the first hard freeze hits, Automated Equipment Identification (AEI) sites become the difference between smooth winter throughput and costly delays. Cold shortens battery life, snow obstructs read fields, and condensation tests every gasket and gland. The solution isn’t guesswork – it’s a repeatable, on-site procedure your technicians can run before the weather turns. Below is a practical, field-tested workflow that folds routine inspection into targeted winterization steps so your readers, antennas, presence sensors, and power systems stay reliable from first flake to last thaw.

Why Winter Punishes AEI Sites

• Cold + batteries: Capacity drops sharply below freezing, causing brownouts and corrupted reads.
• Snow/ice + hardware: Drifts bury cabinets and coat antennas, while rime ice stresses mounts.
• Moisture + enclosures: Freeze–thaw cycles sneak past tired gaskets, expanding inside housings and accelerating corrosion.
• Access constraints:  Once roads get slick, every minor failure becomes a major logistics challenge.

The Field-Tech Winterization Procedure

Run this procedure in early fall, then verify with a quick follow-up after the first prolonged cold snap.

1) Check the battery holding ability

Perform a load test on each battery string and verify charge controller/regulator performance. Confirm low-voltage cutoffs to prevent deep discharge. Replace marginal batteries now – capacity that looks “okay” at 50°F can collapse at 10°F.

2) Check the wheel sensor attachment (torque bolts)

Inspect mounts, brackets, and fasteners for corrosion or elongation. Re-torque to spec so vibration, thermal contraction, and snowplow shock loads don’t loosen the assembly. Confirm cable strain relief and intact drip loops.

3) Calibrate wheel sensor and presence loop (mostly a check)

Validate calibration against known traffic or test tools. Confirm presence loop sensitivity is appropriate for winter conditions (e.g., compensating for packed snow or debris). Record baseline readings so you can compare remotely mid-season.

4) Maintain hut air filters

Swap or clean filters to ensure stable airflow and reduce internal condensation. Restricted airflow creates hot spots that later swing cold, driving moisture into connectors and boards.

5) Turn off or close the vent

For enclosures with seasonal venting, disable or close exterior vents before sub-freezing weather to limit moist air exchange and wind-driven snow ingress. Verify weather seals and gaskets seat properly after closing.

6) Turn on the heater

Enable enclosure heaters or heat-trace where installed. Check thermostats and safety cutouts. For solar-powered sites, confirm heater duty cycles won’t outstrip winter energy budgets.

7) Visually inspect for damage

Walk the entire site: look for cracked radomes, warped doors, missing fasteners, sun-brittled glands, chafed jackets, and conduit low points that can collect water. Re-terminate any corroded connectors and apply dielectric grease where appropriate. Realign antenna/readers as needed.

8) Exterminate insects and rodents (sometimes snakes)

Pests compromise seals, chew insulation, and block fans. Remove nests, treat entry points, and install screens where permissible. Follow local regulations and safety practices; use appropriate PPE and licensed services where required.

Documentation, Spares, and Remote Monitoring

Label each hut with site ID, emergency contacts, and QR codes to schematics – a glove-friendly way to pull up drawings in the dark. Stage winter spares (gaskets, fuses, glands, connectors, a cold-rated battery) along your most weather-exposed corridor. Finally, enable remote health checks – battery voltage, internal temperature, and read-rate alerts – so you can catch anomalies without rolling a truck.

A Preventive Rhythm That Pays Off

• Pre-season (early fall): Run the full procedure above.
• First freeze follow-up: Quick verification – battery trends, heater operation, enclosure temps.
• Mid-winter checks: Remote telemetry review every 30 days; dispatch only if metrics drift.

This rhythm creates season-long reliability – fewer emergency callouts, longer hardware life, and higher confidence in read completeness when operations are most fragile.

How We Can Help

Need an extra set of hands or a second set of eyes? We can audit sites, execute the full winterization procedure, and set up remote dashboards to watch the same KPIs your team cares about. The result: dependable identification and data capture, no matter what the forecast says.

Ready to winterize? Book a pre-season walkthrough and battery test this week to make winter a non-event for your AEI network.