How We Optimised a Cost-Effective Digital Instrument Cluster for a Leading Mobility Supplier

The client’s vision is to integrate a modern digital instrument cluster for their cost-sensitive EV two-wheeler platforms while operating within strict power and hardware constraints. Existing implementations struggled with inconsistent system updates, UI lag, limited connectivity, and a lack of OTA support, making it difficult to reliably present critical vehicle data or to introduce connected features such as keyless entry and rider personalization.

So the primary objectives were to:

• Develop a responsive digital instrument cluster capable of displaying critical vehicle information accurately in real time on low-spec hardware
• Improve UI smoothness and responsiveness to ensure consistent visual updates across dynamic vehicle speeds and operating states
• Enable reliable data handling through filtering and validation of sensor inputs for speed, battery, range, and fault indicators
• Introduce OTA update capability to support remote software updates and feature enhancements without hardware changes
• Enable secure keyless entry via NFC to enhance rider convenience and vehicle security
• Enrich rider experience through Bluetooth-enabled features such as notifications, personalization, and wallpaper switching
• Design a scalable and modular cluster architecture adaptable across multiple vehicle variants, display sizes, and future HMI enhancements

Our automotive engineering team conducted a detailed evaluation of the existing instrument cluster and identified limitations that affect display performance, data accuracy, and flexibility. We developed an optimized digital instrument cluster architecture for low-power embedded platforms, integrating real-time data processing, hardware-accelerated rendering, secure access, connectivity, and OTA update support.

The solution was designed as a modular and scalable framework, enabling reliable vehicle data visualization, seamless software updates, and support for evolving features such as NFC-based keyless entry and Bluetooth-enabled personalization while maintaining cost and power efficiency.

This approach enabled iterative feature refinement and rapid concept validation through software-led updates, eliminating the need for hardware changes.

Key Highlights

A robust data pipeline was developed to process inputs from CAN, UART, SPI, and I2C interfaces, applying filtering and validation to handle noisy sensor data. This enables smooth, accurate, and real-time visualization of speed, battery status, range, and fault indicators without flicker or latency.

Enhanced User Interaction

• UI and rendering logic were optimized using hardware-accelerated graphics (OpenGL ES, DRM), delivering fluid animations and low-latency interaction across dynamic vehicle speeds and operating states, even on resource-constrained hardware.

OTA Update Capability

• Over-the-air update support was integrated to enable remote software upgrades, security patches, and feature enhancements without hardware changes, supporting iterative refinement and faster rollout across the vehicle lifecycle.

Keyless Entry via NFC

• A secure NFC-based keyless entry mechanism was implemented to enable a two-step vehicle start process, combining physical key activation with NFC authorization to improve security while keeping the user experience simple.

Bluetooth-Enabled Features

• Bluetooth connectivity was enabled to support rider notifications, wallpaper switching, and personalization features, extending the digital cluster beyond basic instrumentation for a connected user experience.

Scalable & Modular Architecture

• The cluster architecture was designed to scale across multiple vehicle variants, display sizes, and HMI frameworks (Embedded Wizard, LVGL, Qt), enabling standardization across the vehicle portfolio and faster time-to-market.

Secure Boot Implementation

• Secure boot mechanisms using hashing algorithms and encrypted keys were implemented to protect firmware integrity and prevent unauthorized modifications, ensuring system reliability and security.

Cost-Effective Design

• Cost efficiency was achieved through a cohesive hardware–software design, using a low-cost microcontroller with built-in graphical capabilities that eliminated the need for a separate graphics chipset or external memory. Further BOM cost reductions were realized through optimized hardware design that minimized expenses for power, PCB display, and connectors.

• Improved Reliability with Real-Time Vehicle Data Accurately Displayed with Minimal Lag 
• Enhanced User Experience Through Smooth Graphics, Responsive UI, Keyless Entry, and Bluetooth Features
• Faster development and updates via OTA support, reducing dependency on physical service interventions
• Scalable Solution Supporting Multiple Vehicle Variants, Screen Sizes, and Future HMI Enhancements
• Production-Ready Platform Validated for Cost-Sensitive EV Two-Wheeler Applications