Background

As electric vehicles (EVs) become a mainstream mode of transportation, the supporting infrastructure must evolve just as rapidly. In particular, smart EV charging stations are playing a critical role in ensuring efficient, safe, and intelligent energy delivery. One leading EV charging provider in Southeast Asia is transforming the way public charging stations operate—by integrating intelligent edge computing into each of its chargers. These stations not only recharge vehicles but also collect, process, and transmit data in real time to ensure optimal performance and user experience. To realize this vision, the company sought a next-generation industrial computing solution to serve as the backbone of its smart charging network.

The Company

The customer is a fast-growing EV infrastructure company deploying a network of Level 3 DC fast chargers across city centers, industrial parks, and highway rest stops. These fast chargers provide high-speed energy delivery in under 30 minutes and are equipped with interactive displays, payment interfaces, and advanced diagnostics. To manage these complex systems, the company requires robust edge computing capabilities that can process sensor data, enable remote diagnostics, support real-time billing systems, and maintain connectivity to the cloud.

The Challenges

As the network expanded, it became clear that conventional embedded controllers used in earlier charging stations were inadequate for large-scale deployment. Each charging station needed a compact but powerful computing core that could withstand harsh outdoor conditions, interface with a variety of subsystems, and support remote monitoring and updates.

Several challenges emerged:

1. Environmental Stressors

The charging stations are installed in semi-outdoor locations exposed to fluctuating temperatures, humidity, and dust. A fanless, wide-temperature-range solution was essential to ensure uninterrupted 24/7 operation.

2. Multi-Protocol Connectivity

Each charger needed to communicate with different components—payment terminals, energy meters, cloud platforms, and mobile apps. This required rich I/O support including RS-485, CAN, 4G/5G, and Ethernet.

3. Limited Space and Power Budget

The computing unit had to fit inside a compact, IP65-rated enclosure already occupied by other electrical components. High energy efficiency and passive thermal performance were key.

4. Vendor Compatibility Issues

Many off-the-shelf PCs lacked the necessary I/O flexibility or failed thermal benchmarks during internal testing. Others were over-specified with unnecessary rugged features that added cost without real benefit in this semi-protected environment.

The Solution

Once InnoAioT understood the charging station manufacturer’s pain points, we suggested the EFIC-2000CD 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 EFIC-2000CD 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 EFIC-2000CD 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 EFIC-2000CD 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 EFIC-2000CD 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 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.

Conclusion

The integration of the EFIC-2000CD IoT gateway has enabled the next-generation EV charging station. It successfully addressed key operational challenges and enabled real-time performance in harsh environments.