WIFI CLOUD MODULE DEVELOPMENT

ENHANCING CONNECTIVITY, FUTURE-PROOFING OPERATIONS

Kärcher is committed to driving innovation that enhances customer experiences and ensures seamless product connectivity. With the development of a WiFi Cloud Module (WCM), the company aimed to enable smart connectivity across a broad range of retail products while maintaining top-tier performance and security.

From the outset, scalability and flexibility were key priorities. Kärcher sought a solution that works independently of specific hardware components, providing resilience and adaptability in a rapidly changing market.

The global semiconductor shortage of the early 2020s further validated this strategic direction. It underscored the risks of traditional hardware dependencies and the need for future-proof, software-driven solutions. By addressing these challenges, Kärcher has not only strengthened its product portfolio but also taken a decisive step toward more resilient and connected technologies.

DEVELOPING A CLOUD-ENABLED, SCALABLE, HARDWARE-AGNOSTIC SOLUTION

Zoi provided a customized solution to Kärcher's challenge by developing a WCM that reduces hardware dependencies by utilizing an open-source real-time operating system called Zephyr RTOS and connecting it to AWS cloud services.

Why Zephyr RTOS? It offers several benefits that make it popular for embedded systems and IoT applications. These include multi-architecture support, hardware independence, robust security, and modular scalability. The system also includes rich features like Bluetooth support, power management, and firmware updates over the air (FOTA), all valuable for IoT applications.

Through AWS cloud services integration, this solution provides secure cloud communication. Kärcher can now receive device status and telemetry data in real-time. They can also execute remote commands across their entire connected device network.

With this cloud-enabled, flexible, and scalable solution, Zoi enabled Kärcher to stay ahead of the curve.

A WCM WITH THE USER AT IT’S HEART

The technical implementation was based on 5 main pillars including the operating system, architecture design, IoT security, user experience and module integration.

Operating System - Zephyr's Versatility and Flexibility for IoT Development

Zephyr's versatility and flexibility proved key to developing the WCM. The system provided several advantages for this project. :

• It's hardware-agnostic, meaning the WCM integrates easily into various products without custom builds for each device's hardware.
• Its modular architecture enabled Zoi to include only the features Kärcher required, reducing the module's overall footprint.
• Zephyr's scalable design means companies like Kärcher can easily upgrade and adapt their products as new hardware platforms become available.

Overall, Zephyr provided a highly versatile, secure, and scalable foundation that helped Zoi develop a WCM meeting Kärcher's specific requirements in a timely and cost-effective manner.

ARCHITECTURE - SEAMLESS COMMUNICATION USING AWS SERVICES

The user interacts with their device through a mobile app. Initially, they connect via Bluetooth (BLE) to the WCM. The WCM then establishes an internet connection over WiFi and communicates with AWS IoT Core using the MQTT protocol. This enables secure data exchange between the device and the cloud.

AWS IoT Core allows the product to send data, such as status updates or telemetry, to the cloud. Meanwhile, users can send remote commands from the app to control their device. This setup also supports Firmware Over-the-Air (FOTA) updates, enabling seamless software updates through the cloud.

The result is real-time control, monitoring, and secure cloud communication that enhances both functionality and user experience.

This architecture diagram below (Figure 1) shows how the WCM acts as the central relay between a product, the cloud and a mobile app using AWS IoT services. 

Figure 1: Architecture diagram for the WCM.

IOT SECURITY - ENSURING SAFE AND RELIABLE CONNECTIVITY

Today's IoT landscape presents significant security challenges. Cyberattacks on connected devices can cause serious harm to both users and companies. IoT devices must include robust security features to prevent unauthorized access.

At Zoi, IoT security is fundamental to any connected device. The WCM was designed with security as the top priority. The module uses Bluetooth Low Energy (BLE) encrypted communication for secure device onboarding. This ensures only authorized users can connect to the device.

For cloud communication, the module uses MQTT authenticated with certificates. This provides encryption and authentication at the message level. The module also supports secure firmware upgrades through FOTA, ensuring updates happen safely over the air. Finally, a secure boot process ensures that only authorized and validated firmware loads onto the device.

By prioritizing security in the WCM design, Zoi ensured that Kärcher can provide customers with a secure and reliable IoT-enabled product.

USER EXPERIENCE - EFFORTLESS CONTROL FOR USERS

Providing a seamless user experience is crucial for any connected device. The WCM prioritizes user-friendly features throughout the customer journey.

The device onboarding process through BLE communication with a mobile app is straightforward and intuitive. This creates a hassle-free setup process for Kärcher's customers. Users simply tap "Add a new Device" and enter their WiFi network credentials.

Once onboarded, customers use the mobile app to control and monitor their devices in real-time. This provides a convenient and user-friendly experience. Users also receive device status notifications and alerts in real-time, keeping them always informed about their devices' status.

Firmware upgrades ensure that customers always have access to the latest features and functionality, without any disruptions. By prioritizing user experience in the WCM design, Zoi provided Kärcher with a highly reliable, scalable, and easy-to-use solution that meets modern customer demands.

MODULE INTEGRATION - STRAIGHTFORWARD PRODUCT INTEGRATION

Integrating the WCM module into a product is simple and straightforward. It can be achieved with minimal disruption to existing operations. The module includes the complete IoT stack, including secure communication with AWS cloud services.

This enables easy integration into a wide range of products through a standard serial communication interface. Product teams don't need IoT expertise, which reduces time-to-market significantly. For Kärcher, this means faster innovation cycles and quicker responses to market opportunities.hly reliable, scalable, and easy-to-use solution that meets modern customer demands.

ABOUT KÄRCHER

At Kärcher, a 17,000-strong team in 85 countries and 170 companies work together to make the world a little cleaner. As the market leader in cleaning technology, Kärcher offers global cleaning and care solutions and achieved a turnover of 3.446 billion euros in 2024.