Future-Proofing EV Charging Stations with Industrial-Grade IoT Gateways

 

With a growing network of over 900 EV charging stations across the United States and Canada, this smart charging solution has established itself as a leader in the industry. Over the past seven years, the company has developed one of the fastest EV charging systems, successfully enabling seamless coast-to-coast charging routes. To further enhance and expand its charging infrastructure, the company has integrated an industrial-grade IoT gateway, optimizing performance and reliability for its next-generation smart EV charging stations. This case study highlights how this technology is driving innovation and improving the efficiency of EV charging networks.

 

Challenge:

• Ensuring durability to withstand extreme weather conditions 
• Enabling real-time monitoring and guaranteeing uninterrupted 24/7 operations 
• Integrating multiple IoT components, such as payment terminals and display screens, into a unified system 
• Implementing secure wireless connectivity for seamless data transmission to the cloud
• Providing additional I/O support for on-site diagnostics and maintenance

Solution:

• Compact design with DIN Rail mounting compatibility for easy installation
• Extensive built-in connectivity to support multiple IoT devices
• Seamless integration with EV charging management software
• Rugged construction, designed specifically for operation in harsh environments
• Industrial-grade alternative to consumer-based solutions like Raspberry Pi or NUC 

Benefits:

• Strong partnership and responsive communication throughout the project lifecycle
• Expert engineering and supply chain support to ensure seamless integration and deployment
• Access to advanced manufacturing solutions for scalable and efficient production

The Challenge

Following a successful proof of concept using a Raspberry Pi, the charging station manufacturer required a rugged, industrial-grade IoT gateway for large-scale deployment. These smart EV charging stations needed to operate reliably in harsh environmental conditions, from freezing winters to scorching summers, while also meeting critical performance requirements for continuous 24/7 operation.



  
Ensuring 24/7 Reliability
Uninterrupted uptime is crucial for the efficiency of an EV charging station network. These stations operate in diverse environments, facing extreme weather conditions. While housed in weatherproof enclosures, the IoT gateway must be resilient enough to withstand freezing temperatures and intense heat. The manufacturer required a rugged and reliable solution capable of maintaining continuous 24/7 operations, as any downtime could disrupt EV drivers and negatively impact the network’s reputation.


Real-Time Processing for Seamless Performance
To deliver a smooth and responsive charging experience, real-time data collection and monitoring were essential. The IoT gateway needed to gather and transmit data from multiple connected devices to the cloud instantly, enabling fast and efficient charging sessions. Additionally, seamless integration with the EV charging management software was critical to ensure real-time reporting, billing, and system monitoring.


Advanced IIoT Connectivity for Wireless Communication
For a fully optimized EV charging station, the IoT gateway had to streamline communication between multiple station components. Along with supporting various wired connections, it also needed to enable wireless connectivity, particularly 4G/LTE, to securely transmit mission-critical data to the cloud. This wireless capability ensures seamless remote monitoring, diagnostics, and system management.


 

The Solution: RCO-1000-EHL Ultra-Rugged Fanless Mini PC

After assessing the challenges faced by the charging station manufacturer, C&T recommended the RCO-1000-EHL Series, an industrial-grade IoT gateway that met all deployment requirements. This fanless mini-computer has already proven its reliability in similar EV charging station applications, ensuring seamless operation in demanding environments.




Durable, Industrial-Grade Design
Designed as a rugged alternative to consumer-grade NUCs, the RCO-1000-EHL Series is built with industrial-grade components to endure harsh environmental conditions, making it the perfect fit for EV charging stations. Its fanless, cableless architecture enhances reliability by eliminating common failure points associated with commercial solutions.

Additionally, its ultra-compact, DIN rail-mountable design allows for effortless integration into space-limited enclosures already containing other essential equipment. Beyond EV charging applications, this gateway has been successfully deployed in challenging environments such as wastewater treatment facilities and remote oil and gas sites. 

Intel Atom Processor for Real-Time Computing
Equipped with an Intel Atom x6425E processor, the RCO-1000-EHL ensures efficient real-time data processing while maintaining low power consumption. With time-sensitive networking features and an extended temperature range, it is well-suited to support the EV charging management platform and various station components. Additionally, being part of Intel’s embedded product lifecycle support program, the processor ensures long-term reliability with a 10-year lifecycle, making it a stable choice for sustained deployment.






Extensive IoT Connectivity for Seamless Integration
The RCO-1000-EHL excels as an IoT gateway, offering a wide range of connectivity options, including high-speed LAN, USB, and legacy COM ports to support essential station components such as payment terminals, display screens, and sensors. Additionally, it features onboard wireless connectivity, including 4G/LTE and 5G support, ensuring real-time data transmission to the cloud for remote monitoring and management. By consolidating data from various IoT devices into a single, centralized gateway, it enables efficient communication with cloud-based command centers for advanced data analysis.

The Benefits

Beyond the RCO-1000-EHL Series serving as the ideal IoT gateway for EV charging stations, collaborating with C&T offers significant advantages, including cutting-edge manufacturing capabilities and dedicated technical support from experienced teams.




Expert Engineering & Supply Chain Support
C&T’s engineering and supply chain specialists provide comprehensive assistance from initial design to full-scale production. Engineers work closely with manufacturers to optimize firmware and BIOS configurations, ensuring seamless integration with the EV charging management platform. Additionally, C&T’s transparent supply chain management allows EV charging networks to plan deployments strategically, ensuring on-time deliveries and meeting critical production deadlines.



Scalable Manufacturing Through U.S. Partnership
To support the expansion of EV charging networks, C&T collaborates with a trusted manufacturing partner in the U.S. to provide high-volume production capabilities tailored to deployment needs. This partnership ensures efficient, localized manufacturing, enabling EV charging station providers to scale seamlessly while maintaining high-quality standards. By leveraging C&T’s engineering expertise and its U.S.-based production network, EV charging manufacturers can meet both current demand and future growth objectives with speed and reliability.


 

Conclusion

By integrating the RCO-1000-EHL Series IoT gateway, this next-generation EV charging station network has overcome key operational challenges, achieving real-time performance and reliable functionality in demanding environments. C&T’s ongoing collaboration with EV charging providers continues to support the expansion of a smarter, more efficient charging infrastructure, shaping the future of electric transportation with innovative and dependable solutions.

 

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