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Intelligent Control Centre for Electric Mobility

THE CHALLENGE

A leading inverter and charger manufacturer had the strategic goal of building an Intelligent Control Centre at its headquarters for global supervision of its electric charging fleet. However, it faced critical limitations in its legacy infrastructure:

  • Technological Bottlenecks: The existing architecture (based on EC2 instances and Mosquitto) represented the weakest link, limiting the scalability and reliability needed for mass deployment.
  • Data Inefficiency: The messaging model was not optimised, generating between 30 and 40 million daily messages with redundant or low-value information, raising costs and hindering real processing.
  • Operational Blindness: The inability to generate certain critical KPIs due to missing origin fields prevented a complete view of charger performance.

THE SOLUTION

GALEO designed and implemented PE-NEXUS, a highly scalable and robust digital architecture built on AWS managed services.

The solution spans from data ingestion to consumption in business applications:

  1. Robust Cloud-Native Architecture: Migration from legacy systems to a serverless infrastructure on AWS, designed to support massive workloads.
  2. Messaging Optimisation (“Vitaminised OCPP”): The processing logic was reprogrammed to manage messages under the OCPP protocol, optimising ingestion and reducing data noise to focus on valuable information.
  3. High-Performance Real-Time API: Development of an API capable of supporting millions of new daily records and hundreds of thousands of daily queries. This layer feeds web operation and supervision applications, serving critical data such as live sessions, charger status, and telemetry.
  4. Bidirectional Interaction: Implementation of write functions to Modbus and OCPP databases, enabling not just reading but active management of parameters on the devices.

BUSINESS IMPACT

The project has laid the technological foundations for the company’s future Mobility 2026 Control Center.

  • Massive Scalability: The platform processes millions of records daily, ensuring that the growth of the charging fleet does not compromise system performance.
  • Operational Visibility: New web applications, powered by the data platform, allow operators to visualize active charging sessions, alerts, and network status in real time.
  • Cost Efficiency: The optimization of the data model and the migration to managed services have resolved inefficiencies from the previous architecture, reducing operational costs associated with redundant data processing.
  • Corporate Integration: Ability to integrate static data from corporate systems such as SAP, enriching operational analytics with business data.

ARCHITECTURE & TECHNOLOGY

The solution stands out for its use of Infrastructure as Code (IaC) and real-time analytics technologies.

  • Core Cloud: AWS Managed Services (AWS IoT Core, AWS Lambda).
  • Storage & Processing: Amazon DynamoDB, Amazon Aurora (PostgreSQL), Data Lake.
  • Real-time Analytics: Use of Tinybird for ultra-low latency analytical endpoints.
  • Infrastructure: Automated deployment using Terraform.
  • Protocols: MQTT, OCPP, Modbus.
  • Scalability & Volume: Management of more than 2,500 connected chargers, with an ingestion of ≈25 million events per day and 66.5 GB of daily processed data.
Intelligent Control Centre for Electric Mobility,

CUSTOMER REVIEW

“PE-NEXUS has completely eliminated the deficiencies of our legacy systems. We now manage to filter the millions of daily messages from our global fleet and have precise, scalable, and highly cost-efficient real-time control.”