This electric vehicle charging station solution network has successfully integrated a network of over 900 charging stations across the United States and Canada. With over 7 years of operations, it has pioneered one of the fastest electric vehicle (EV) charging solutions and has completed coast-to-cost charging routes to strengthen the smart EV charging station infrastructure. This case study explores how the company continues to expand its charging network and enhance the nation’s EV infrastructure by adopting an industrial-grade IoT gateway to power and consolidate its next-generation EV charging solution.
Challenge:
The transition from a Raspberry Pi-based proof-of-concept (POC) to a scalable, real-world deployment came with unique challenges, including:
- Reliability to withstand extreme temperature conditions
- Enable real-time monitoring and maintaining 24/7 operations
- Consolidate various IoT devices such as payment systems, display screen, etc.
- Integrate wireless connectivity to relay data securely to the cloud
- Support additional I/O for on-site troubleshooting and maintenance
Solution:
The RCO-1000-EHL Series Fanless Mini Computer was selected as the ideal industrial IoT gateway for this EV charging station application due to its:
- Ultra-compact form factor and compatibility with DIN Rail mounting
- Comprehensive on-board connectivity for various IoT devices
- Compatibility with EV charging management software platform
- Purpose-built to operate in harsh environments
- An industrial alternative to a Raspberry Pi or NUC
Benefits:
- Close collaboration and dedicated sales communication throughout the project
- Expertise in engineering support and supply chain management
- Access to Premio’s advanced manufacturing capabilities for scalable production
The Challenge
After a successful proof of concept for the next-generation charging station solution using a Raspberry Pi, the charging station manufacturer needed an industrial-grade IoT gateway solution for their real-world deployment. These smart EV charging station dispensers will be implemented in locations with extreme weather conditions from freezing cold winters to blistering hot summers, not including the several vital requirements that are required for robust 24/7 operations.
In Need of 24/7 Reliability
For an EV charging station network to function effectively, a constant uptime is critical. These charging stations will operate in locations that expose them to a wide range of environmental challenges. Although protected by a weatherproof enclosure, the IoT gateway solution is required to withstand extreme temperatures from subzero winters to sweltering summers. The manufacturer needed a robust solution that could endure these harsh conditions while maintaining 24/7 operations as downtime could disrupt an EV drivers' plans and tarnish the network’s reputation.
Real-Time Performance Requirement
Real-time data processing and monitoring are essential for smart EV charging stations to provide a smooth user experience. The IoT gateway solution needed to collect data from multiple connected devices to rapidly relay to the cloud network for an instantaneous charging process. Furthermore, the IoT gateway needed to be compatible with the network’s EV charging management software delivering real-time reporting, billing, and monitoring.
Essential IIoT Connectivity For Wireless Communications
Compatibility with the EV charging station dispenser devices is significant to streamlining the complexities of the overall system. The IoT gateway solution needed to provide the necessary IoT connectivity options to consolidate various charging station devices. In addition to physical connections, it had to support wireless communications, specifically 4G/LTE, to process mission-critical data to the cloud network for remote monitoring and management.
The Solution
Once Premio understood the charging station manufacturer’s pain points, we suggested the RCO-1000-EHL Series that best meets their deployment requirements. This fanless mini computer serves as an industrial-grade IoT gateway that have proven successful in operating seamlessly in other charging station-related deployments.
Ruggedized Industrial-Grade Computing Designs
The RCO-1000-EHL Series was purpose-built as an industrial NUC alternative engineered with industrial-grade components to withstand harsh environmental conditions; making it ideal for rugged deployments like EV charging station. Its fully fanless chassis and cableless design ensures protection against common failure points in consumer-grade solutions.
Additionally, its DIN rail mountable, ultra-compact form factor seamlessly retrofitted into the space-constrained dispenser enclosure that is already occupied with other equipment. The RCO-1000-EHL Series has been effectively utilized in other applications where conditions are as challenging or even more extreme, including wastewater management and remote oil and gas well sites.
Intel Atom Processor for Real-Time Processing
As an IoT gateway, the RCO-1000-EHL delivers real-time performance by leveraging an Intel Atom x6425E processor. This processor emphasizes low-power utilization, time-sensitive networking features, and an extended operating temperature range to enable the EV charging management platform and power various dispenser equipment. In addition to processing data in real-time, the Intel Atom x6425E is part of Intel’s embedded product lifecycle support program, ensuring a 10-year lifecycle for long-term deployment consistency and support.
Comprehensive IoT Connectivity
The RCO-1000-EHL truly shines as an IoT gateway by featuring rich I/O connectivity options, from high-speed LAN and USB to legacy COM, to support the various IoT devices including the payment terminal, display screen, and other sensors. It also provides on-board wireless connectivity with 4G/LTE and even 5G. By consolidating all the data from diverse IoT devices to a single gateway, it can efficiently relay mission-critical information to the cloud and command centers for further analysis.
Certified for Safety, Qualified for Edge-to-Cloud
For deployment peace of mind, the RCO-1000-EHL has undergone stringent safety standards compliance testing to achieve UL Listed, FCC, and CE certifications. In addition to safety certifications, it is also an AWS IoT Greengrass-qualified device which allows for seamless compatibility with the AWS platform for edge-to-cloud operations. This combination of certifications and qualification demonstrated the RCO-1000-EHL's capabilities in rigorous edge deployments.
The Benefits
Outside of the RCO-1000-EHL Series as the ideal IoT gateway solution for the EV charging station solution, establishing a partnership with Premio provides valuable benefits including manufacturing capabilities and close support from respective teams.
Proactive Engineering & Supply Chain Expertise
Premio’s dedicated engineering and supply chain teams provide hands-on support from design through to long-term production. Our engineers were available to collaborate closely to optimize firmware and BIOS settings, ensuring seamless compatibility with EV charging management software. The supply chain team ensured full shipment transparency, enabling EV charging networks to strategically plan for timely deliveries and meet specific deadlines accordingly.
Scalable Manufacturing Capabilities
Located in Los Angeles, California, Premio operates a state-of-the-art 150,000 sq ft facility designed to accommodate high-volume production demands. As the EV charging station network decides to expand their infrastructure, Premio can play a critical role in meeting the manufacturer’s current deployment requirements while ensuring seamless support for future growth.
Conclusion
The integration of the RCO-1000-EHL Series IoT gateway has enabled the next-generation EV charging station. It successfully addressed key operational challenges and enabled real-time performance in harsh environments. Premio’s ongoing partnership with the EV charging network continues to drive the expansion of the nation’s EV infrastructure, delivering smarter, more reliable station solutions for the future of electric transportation.