An Integrated Hardware Framework for Mitigating Critical Operational Threats in Next-Generation Battery Swapping Stations

Hardik Mohanbhai Agravatt; Indrajit Nandlal Trivedi; Snehal Vijaykumar Purani

An Integrated Hardware Framework for Mitigating Critical Operational Threats in Next-Generation Battery Swapping Stations

Author(s)	Mr. Hardik Mohanbhai Agravatt, Dr. Indrajit Nandlal Trivedi, Mr. Snehal Vijaykumar Purani
Country	India
Abstract	Battery swapping stations are gaining traction as a workable route to shrink the downtime that ordinarily accompanies electric-vehicle charging; even so, deploying them in the field exposes a cluster of operational risks that span energy pilferage, weak traceability of battery health, and breaches of physical security. A consolidated, inexpensive, hardware-oriented mitigation framework is proposed in this work, organised around six cooperating modules. Battery voltage is acquired through a resistive divider that feeds a microcontroller analogue-to-digital converter, and the state of charge is reconstructed from the recovered reading. Access is governed by a Bluetooth authentication layer built on the HC-05 module together with relay switching, so that charging remains blocked until the supplied credentials are matched against stored ones. Additional platform headroom is obtained by migrating from 8-bit devices to the ESP32, whose dual-core processor, 12-bit conversion, and on-chip Wi-Fi permit sensing, logging, and connectivity to proceed together. Cycle history is captured with an ACS712 current sensor combined with temporal filtering and is retained in on-board EEPROM or flash so that it survives power interruptions. Physical protection is delivered by a subsystem that combines a NEO-6M receiver for live positioning, a SIM900A module for mobile notification, and ultrasonic ranging for tamper sensing. A swap-decision pipeline finally unites a MATLAB interface with ThingSpeak analytics to derive a dynamic swap price from a fixed component, the energy delivered, and a health-dependent penalty factor. The resulting architecture is intended for rapid replication on academic and early-stage industrial testbeds, and it supplies a structured engineering blueprint for secure, health-aware, and auditable swapping operations
Keywords	Battery Swapping Station, Unauthorised Charging, Bluetooth Authentication, EEPROM Logging, Charging Cycle Counting, Voltage Divider, State of Charge Estimation, State of Health Estimation, MATLAB Interface, ThingSpeak, Operational Threats
Field	Engineering
Published In	Volume 8, Issue 4, July-August 2026
Published On	2026-07-05

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CrossRef DOI prefix of IJFMR is 10.36948/ijfmr

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An Integrated Hardware Framework for Mitigating Critical Operational Threats in Next-Generation Battery Swapping Stations

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