Smart EV Charging Smart Meter Solution
A scalable and secure EV charging smart meter infrastructure was developed to support automated fleet provisioning, real-time charge monitoring, OTA updates, and secure device-to-cloud communication. The system enabled seamless deployment and management of smart charging meters in residential and commercial environments.
Location
India
Clients
Truswitch
Project Duration
2 months
Industry
Electric Vehicle Infrastructure / Smart Energy
Services Provided
Architecture Engineering
Designed a modular backend and firmware system integrating AWS services and secure communication protocols for provisioning and device management.
Firmware Development
Engineered the firmware for the smart meter, supporting X.509 certificate deployment, secure MQTT communication, and BLE/WiFi provisioning.
Mobile App Integration
Enabled mobile-based fleet provisioning and device onboarding via captive portal and BLE, allowing real-time credential transfer and setup.
Cloud Infrastructure Setup
Leveraged AWS IoT Core, Lambda, API Gateway, and DynamoDB for secure messaging, device lifecycle management, and data operations.
Certificate Management
Deployed a custom Certificate Vending Machine (CVM) for X.509 certificate issuance, ensuring secure device provisioning workflows.
Secure Provisioning & Communication
Implemented AWS IoT fleet provisioning using pre-generated and on-demand certificates deployed via the mobile app.
Backend Development
Built logic for heartbeat, charging control (start/stop), OTA, health monitoring, session billing, and usage analytics.
Quality Assurance
Validated end-to-end functionality including provisioning, data transmission, reconnection handling, and OTA reliability.
Technologies Used
Firmware
- C / C++ for embedded systems
- X.509 Certificate-based authentication
- Custom captive portal for provisioning
- BLE and WiFi Stack
Mobile App
- React Native / Native Android / iOS
- Captive portal and BLE-based device onboarding
- Integration with AWS services
Cloud & Backend (AWS)
- AWS IoT Core – Secure MQTT messaging and device registry
- AWS Lambda – Stateless business logic execution
- Amazon API Gateway – Secure REST APIs
- Amazon DynamoDB – NoSQL data storage for user and device metadata
- Amazon S3 – Storage for logs and OTA payloads
- AWS Cognito – User authentication and access control
- AWS Amplify – Frontend deployment and CI/CD
- Amazon SNS / SES – Notification and email alerts
- PostgreSQL – Persistent relational storage (if used)
- AWS Greengrass – Local edge processing and logic distribution
- AWS CloudWatch – Monitoring and log aggregation
Challenges
- Enable secure, scalable fleet provisioning of IoT devices in field conditions
- Provide OTA firmware updates and health monitoring at scale
- Offer a user-friendly mobile onboarding experience via BLE and captive porta
- Ensure reliable cloud-to-device messaging for start/stop charging commands
- Deliver accurate session billing and device diagnostics for operators
Solution Overview
The architecture was composed of three interconnected components:
1. IoT Device Firmware
- Provisioned via X.509 certificates from the mobile app using a CVM backend
- Established secure MQTT connections with AWS IoT Core
- Exposed a captive portal to the mobile app for WiFi configuration
- Handled runtime logic such as charge start/stop, session tracking, and OTA updates
2. Mobile Application
- Connected to IoT devices via BLE and WiFi captive portal
- Managed X.509 certificate injection and WiFi credentials provisioning
- Interfaced with backend services for project and user association
3. AWS-Powered Cloud Backend
- Secure certificate issuance and validation
- IoT Core for device messaging and topic handling
- Lambda and API Gateway for all business logic operations
- S3 for OTA firmware hosting
- DynamoDB for project, session, and device metadata
- Cognito for user identity and role management
How It Works
The architecture was composed of three interconnected components:
1. Provision & Secure:
Mobile app initiates provisioning using CVM and installs certificates on device.
2. Connect & Configure:
IoT device broadcasts captive portal; user connects and provides WiFi credentials.
3. Operate & Monitor:
IoT device broadcasts captive portal; user connects and provides WiFi credentials.
4. Connect & Configure:
OTA firmware updates, charge control, and device health diagnostics managed remotely.
Results & Business Impact
- Secure, scalable onboarding of EV smart meters through mobile-first provisioning
- Real-time control of EV charging with start/stop commands via MQTT
- Accurate charge session billing and telemetry storage
- OTA update capabilities ensuring continuous feature deployment
- Future-ready architecture for integration with electric utilities and fleet services
Why AWS
AWS was chosen to power this EV infrastructure due to:
- Native support for IoT device provisioning and security
- Scalable, fully managed services that accelerate development cycles
- Strong DevOps toolchain for CI/CD and monitoring
- Rich support for real-time messaging and serverless logic
Key AWS Services Used
Service
Purpose
AWS IoT Core
Secure MQTT messaging and device registry
AWS Lambda
Stateless backend logic for control and monitoring
Amazon API Gateway
Expose RESTful APIs to mobile and web clients
Amazon DynamoDB
Fast, scalable NoSQL storage for metadata and telemetry
Amazon S3
Storage of firmware, logs, and user-generated files
Amazon Cognito
Secure user authentication and access control
AWS Greengrass
Local device logic (optional depending on use case)
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