Every kilowatt counted. Every rupee reconciled.
How Optimworks helps India’s EV charging networks ship reliable Charge Management Systems (CMS), by testing chargers, availability, charging levels and payments end to end, with manual and automation testing working together.
The challenge
India’s EV market is growing fast, and charging operators are scaling networks across cities and highways. Their software has to work with many charger brands, patchy networks and real money changing hands, all at once.
What made it hard
- Multiple charger makes and firmware versions speaking OCPP differently
- Chargers dropping offline mid-session on weak connectivity
- Availability shown in the app not matching the real charger state
- Billing by kWh, time and idle fee, with taxes and refunds
- Frequent releases with little time for full regression
What was at stake
- Drivers reaching a charger the app called “available” but was faulted
- Over- or under-billing that erodes trust and revenue
- Sessions that never stop, or stop with no payment captured
- Support load and lost repeat usage
How Optimworks tested it
Two complementary practices: experienced testers for judgement and edge cases, and automation for speed and repeatability.
Manual testing
-
Charging levels:
AC slow and fast, DC fast (CCS2, CHAdeMO, Type 2), power ramp and cut-off -
Real-charger field checks:
plug-in, RFID, QR start, emergency stop, connector faults -
Availability states:
available, preparing, charging, finishing, faulted, unavailable -
Money scenarios:
partial charge, wallet top-up, failed UPI, duplicate callbacks, refunds -
Exploratory and usability
on driver and operator apps
Automation testing
-
OCPP simulators
to replay charger messages and inject faults at scale -
API automation
for sessions, tariffs, wallets and invoices -
UI automation
for CMS dashboards and mobile apps -
Regression in CI
on every build, with clear pass / fail reports -
Load and soak tests
for many chargers reporting at once
Our approach
Understand the domain
Map charger types, OCPP versions, tariffs and payment rules.
Build the risk map
Rank flows by impact: availability, session control, billing.
Design and execute
Manual test design first, then automate the stable, repeatable flows.
Reconcile the money
Match kWh from the meter to the session, invoice and ledger.
Report and improve
Daily reports, defect trends and release sign-off.
What the client gained
Trust in availability
Charger status in the app matched the field, so drivers stopped arriving at faulted chargers.
Accurate billing
End-to-end reconciliation caught rounding, tax and refund defects before launch.
Faster, safer releases
Automated regression cut validation from days to hours on every build.
Scale-ready platform
Load tests showed how the CMS behaves as the charger network grows.
Tools and standards
Building or scaling an EV charging platform?
Talk to the Optimworks QA team. We will review your CMS, IoT and payment flows and show you where the risks are.
Client details are kept confidential.
