An industrial computer is a specific type of computing system engineered to manage a variety of factory and industrial workloads for machine automation, manufacturing equipment and new-age autonomous robotics. One major benefit from industrial computers is the ability to operate with high reliability in the harshest industrial environments. Most industrial computers share rugged design concepts that utilize fanless cooling technology, cableless connections to eliminate moving parts, and resistance to some level of dust and water intrusion. These key characteristics are some of the greatest advantages for industrial computers because it provides stability and efficiency for many industrial automation deployments that are unable to afford downtime.
How is an Industrial Computer Different Than a Commercial D
esktop C
omputer?
Commercial Dell Desktop Computer
An industrial computer is different from a commercial desktop computer in very specific ways due to its deployment use cases. Although the internal components may seem like ordinary desktop computer components, (CPU, Memory, Storage); but an industrial computer is very different in its distinct rugged design features that are engineered for reliability and precision in industrial automation machines. There are many design features that are integral to the performance and stability of industrial computers that you should compare and evaluate to ensure the best total cost of ownership when integrating computing hardware:
Enclosure form factor:
It is common for industrial computers to undergo harsh factory conditions where exposure to wide temperatures, vibration, and voltage
spike
s can cause harm to a general computer.
Therefore, industrial computers
have internal components made from alloy materials that are strong enough to withstand high
temperatures
and vibrations.
Most external enclosures feature a
robust aluminum chassis that
acts as a heat sink that transfers heat away fr
om critical
internal components
like the central processing unit, memory, and storage.
Industrial Grade Components:
Industrial computers will often times feature industrial grade components that have
been tested
and validated to operate in harsh industrial environments. Everything from the PCB motherboard to the electrical soldered capacitors are specifically chosen and integrated
into a final
industrial computer design that is ready for mass deployment in factory settings.
Protection from
Dust
and
particulate
intrusion
:
Industrial computers are designed specifically for deployment in areas such as factory automation or mining processes where dust and foreign debris is often a common companion. Therefore, industrial computers are designed with rugged design features
that eliminate the need for cooling vents, preventing dust and other particulates in harsh environments to jeopardize the computer and its functionality.
Extreme temperature
: Many industrial applications require computers capable of withstanding extreme operating temperatures. Since computers with fans are subject to failure from dust contamination, these specialized computers are designed with a
fanless system
architecture that utilizes heat sinks and heat pipes to maintain wide operable temperatures. This allows industrial computers to function in harsh environments and where temperatures is often uncontrollable. For example, computers in industrial use cases can support
operating temperatures from –40C to 70
C (-40F to 158F), allowing functionality in both extreme cold and hot applications.
Let's get technical - Read more about the benefits of fanless system architectures for industrial and embedded computers
Shock and Vibration Resistance
: High levels of shock and vibration can be detrimental to a computer that has not undergo extensive design validation and testing. Most industrial computers will feature some level of resistance to these environmental factors and maintain functionality during these specific situations. For example, some industrial automation equipment can create levels of shock and vibration during the manufacturing process that may cause harm to general computers and causing system failures. Support for vibrations levels range from 3-5 GRMS; and shock is often support up to 50G; some industrial computers also can meet stringent military specifications like MIL-STD-810G, for heavy duty military use cases.
I
ngress P
rotection
(IP Ratings)
:
Not only are industrial computers dust proof, they can also be water-resistant to a certain degree. The key for a reliable and rugged computer is to eliminate multiple points of failures, especially from dust and water elements. For example, in industrial applications such as food manufacturing and chemical processing, automation equipment and its computers are often washed down with heated water jets or
cleansing materials
. Therefore, most
industrial
computers
used in those settings
h
a
ve
some levels of IP protections from the design to even special M12 connectors, which will be explained below.
Let's get technical - Read more about what IP rating means and its system of classification for industrial and embedded computers
EMI resistance:
Short for electromagnetic interference (EMI), a naturally occurring phenomena generated when the electromagnetic (EM) field of one device degrades the EM field of another device in proximity. This can lead to the degradation of circuits and may even stop it from functioning. In industrial settings where the existence of different equipment combined with inadequate installations could facilitate the emission of unwanted EM disturbances
and causing signal interference. Therefore, most
industrial computers are properly designed, shielded, and tested
to ensure complete isolation
and
adhere to strict regulatory standards and compliance.
Expandability and L
ongevity:
Industrial computers have more expansion capabilities than commercial computers to include proper support for
many
legacy
devices and applications
.
Many of the components used are available and can last up to 15 years, providing a embedded computing solution for the long-term. This is especially important for industrial factories that may not have the ability to upgrade or retrofit with the latest automation technology every few years. Therefore, most industrial computers today provide a platform to help consolidate multiple workloads that derive from various legacy and up-to-date technological features. One key example is the ability to support legacy analog serial ports versus the latest digital universal serial bus (USB) connectors.
Most Popular I/O Ports Made for
I
ndustria
l Computing Applications
As technological advances in IoT, Big Data, and Machine learning put greater demands on industries like manufacturing and automation, there continues to be a major shift of data and its value across IT and OT efficiencies. In this era of transformation, or what being called “industry 4.0,” more and more devices are being connected to machines; putting an enormous amount of pressure on computing systems to be versatile in its specific functions and workload performances. For example, industrial computers now act as platforms for specific workload consolidation and convergence at the local or edge level. In other words, industrial computing systems now need to be able to manage a variety of data inputs that transmit valuable information for real-time decision making. Therefore, industrial computers support a variety of legacy and new input and output (I/O) ports. Here are some of the most popular I/O ports used in industrial computing deployments today:
Serial ports
are the most common port used for an industrial computer. They are used to communicate with legacy devices that are still being used in factories
today.
While it doesn’t have the fastest data transmission rate, i
t has been proven to be a reliable protocol over may decades.
The legacy serial port has three different modes of function, RS-232/422/485, that vary depending on the application and devices connected.
Video ports
are required in order to display an output. Some of the most common types of video ports are the VGA, DVI, HDMI, and DP.
The
VGA
port
is often used
because it uses analog signals instead of digital ones, allowing for connections with legacy devices. Meanwhile the more modern DVI, HDMI, and DP ports lack the legacy compatibility but offer better maximum resolution and refresh rates
.
DIO/GPIO
are acronyms for digital I/O and general purpose I/O. These are forms of interface used
for
electrical devices
or sensors that lack a common interface. The DIO/GPIO uses digital signals with two possible values generally represented as either ON or OFF. This makes them ideal for sensing switch contacts in industrial settings where many ON/OFF signals need to be sent and received. They can be used in a wide range of applications from alarm sensors to automated production lines.
USB ports
have become the standard port for many devices as the need for more bandwidth increases, which is just not supported by the serial port. Its intelligent power management capabilities allow you to put devices to sleep when not in use, allowing you to connect multiple USB devices without overconsuming power. But it's not the be-all and end-all solution for every industrial
computer because depending on the
application,
both
legacy serial ports and USB ports may be required.
Local Area Network (LAN)
ports provide
a wired network connection up to 1GbE per port. Most industrial computers offer LAN ports that are used to provide uplink and downlink for data from a network infrastructure, providing the necessary data transmission from modems, computers, switches, and routers.
Expert Engineering Tip: For those super heavy duty industrial applications, most I/O ports can be configured with rugged M12 locking connectors for even more durability. Contact Premio's industrial and embedded computing engineers for more information. Contact Us!
But What are M12 Connectors and its Benefits in an Industrial Computer?
M12 connectors are dust and water proof connectors and cables designed to be used in rugged environments where consumer-grade connectors will cause failure. The M12 connector is a favorite in many industries like food processing, beverage manufacturing, vehicle and transportation applications for its robust durability and reliability. This circular connector has a built-in lock mechanism designed to be IP 65 rated or above for rugged water resistance and dust-proof protection from devices to computing machines.
Let's get technical - Read more about the most popular I/O Ports for Industrial Computing and Factory Automation Workloads
Six Real-World Use Cases
that Benefit from
Industrial Computers?
1. Manufacturing and Industrial Automation
Industrial computers are ideal for large scale manufacturing that exceeds the physical imitations of human labor. With their robust build and resistance to environmental factors, industrial computers are relied upon by factories to safely handle automated manufacturing and assembly. In most automation and manufacturing settings, industrial computers are used to manage motion control systems for data logging, inspection, and analysis for better manufacturing productivity. For example, the automotive manufacturing industry has greatly benefited from the development of industrial computers due to its level of automation required. The ability to monitor day-to-day functions, track assets, and analyze data make them an essential requirement in this new industry 4.0 landscape.
2. Interactive Kiosks
Interactive kiosk can be found in your local supermarket, large businesses, and even in airport check-in areas. In recent years, this all-in-one computer system equipped with a fanless industrial computer and interactive HMI has shifted from a novelty to an essential business resource. The compact size and rugged features are designed to endure the rigors of various outdoor environments where constant supervision is unavailable. Many new and emerging markets are beginning to embrace machine automation and self-service kiosks as a means of reducing staffing costs and improving overall customer satisfaction.
3. Automation Inspection, Metrology and Testing Equipment
Industrial metrology is the application of measurements for manufacturing and quality control; Or more specifically, how digital measurement instruments can be utilized to ensure quality in the manufacturing process. Traditionally, quality inspection for parts during the manufacturing process was achieved with small batch sampling to determine overall quality. Today, industrial computers are being integrated with more automation capabilities to ensure even more precision and quality of parts. Also with the combination of machine vision, industrial computers are capable of inspecting components faster and more accurately compared to legacy inspection processes . This creates a more efficient and effective manufacturing process and reduces the number of defective products from going to market, creating better value and productivity for manufacturing.
4. Security and Surveillance
Industrial computers have also been designed for in-vehicle deployments in tough compact conditions such as public transportation and security. Some of the key features like wide temperature support and resistance to shock/vibration are critical for in- vehicle deployments. Industrial computers can also support multiple PoE ports that provide stable connections to IP cameras, which records video footage and improves passenger safety. Ultimately, the fanless rugged design of industrial computers makes it ideal for deployment in rugged surveillance applications.
5. Underground Mining
The harsh nature of underground mining requires specially designed computers able to withstand the demanding conditions characterized by dust, wide temperatures, and vibrations. Industrial computers are extremely robust and can operate in the harshest outdoor environments. These key features are highly beneficial for underground mining equipment because it provides mission critical performance, allowing to capture valuable telemetry for construction and digging sites.
6. Maritime and Military
Military and marine personnel require rugged industrial computers capable of surviving the tough operating conditions on shipboard and ground control operations. Their low maintenance and long operating life meet the requirements and schedules of military operations Additionally, the ruggedized industrial computers can be customized to be fully dust and water resistant to be equally effective across various military applications.
Premio's Industrial Computers
Premio takes the guesswork out of searching for the most appropriate industrial computer by engineering and designing a variety of rugged industrial computing solutions per customer requirements. Each family is purpose-built and validated to ensure high performance and reliability in many industrial applications. With United States product support, customers have turn-key flexibility to fit their special needs.
Premio’s fanless mini PCs are designed for entry-level industrial automation that require low costs and minimal power consumption. The minimalistic design keeps the essential I/O ports and offers universal expansion slots for supplemental configurations for additional I/O ports . The rugged, fanless industrial computers are a more robust fanless computing solution for industrial applications where performance and mission critical reliability are equally important. The in-vehicle computer series is specially designed to cooperate with vehicle sensor protocols like CANBus and is validated to operate in a variety of transportation applications. The machine vision computer supports multiple PCIe/PCI expansion slots and digital I/O functionalities to ensure high quality images and accurate interactions with computer vision sensor devices. Lastly, the waterproof industrial computers are IP rated 65/67 rated and offer robust M12 connectors that make them ideal for applications where water and dust may cause harm to the internal functions of a computer.
Contact Premio engineers to learn about the best industrial computer configuration for your specific deployment.
Industrial PCs and commercial PCs are often being compared to one another in industrial computing applications. This is because they have similar computing capabilities in terms of storage, processing, and communications. However, industrial PCs are designed to have greater reliability, longevity, and flexibility. Here in this blog, we will guide you to uncover the differences between industrial PCs and commercial PCs and what makes the industrial computer a key solution in enterprise-level computing deployments.
What is A Commercial Computer?
A commercial computer is a term to describe a more intensive computing application that demands higher capabilities and reliabilities than normal consumer-grade products. Commonly placed in controlled indoor environments due to its huge size and high-power requirements. For example, a workstation computer is a commercial computer with higher computing performance than a personal computer but is less advanced than industrial computers. Both industrial and workstation computers have a high capacity for GPU interface and high-performance but are different in terms of their ruggedness. Common task commercial computer is used for:
Accessing the internet
Word processing software
Rendering high-definition videos, musics and games
Data analysis
What is An Industrial Computer?
Industrial computers are specifically engineered to work in remote industrial operations with harsh environments that require efficiency and reliable performances. What makes industrial computers special from other computers is their robust designs while maintaining high performance. Industrial computers run more complex tasks such as:
Processing powerful automation software (robot automations)
Data acquisition (predictive maintenance)
High-precision machine vision
Machine-to-machine (M2M) communications
AGV (Automated Guided Vehicle) Systems
Industrial Computers Vs Commercial Computers
There are significant differences between industrial and commercial computers. Many of the differences are related to its ability for continuous operation in harsh environments that can cause detrimental failures. For example, industrial computers are robust in mechanical structure design and use fanless and cable-less designs. These key design features are specifically designed into the industrial computer to ensure durability, reliability, and longevity when exposed to the harshest environments that are susceptible to water, dust, extreme temperature, shock, and vibration.
Designs and Components
1. Fanless Vs. Fan-cooled
Industrial computers are known for their unique and fanless design. Instead of using an active spinning fan for fan cooling, industrial computers utilize heatsinks and heat pipes to dissipate the heat from the hottest part of the computer (CPU) up to the outer portion of the computer. It is a very simple yet effective method in removing heat from critical components to ensure a computer continues to operate. In contrast, many commercial computers use active cooling methods fan-cooled transformers to dissipate heat, something not suitable for industrial applications.
Fanless Computer Designs and How They Work – Premio Inc
2. Cableless Vs. Cabled
Industrial computers eliminate cable usage to reduce the possibilities of loose cables from their connection, withstand external interruption, and cable burned out. Instead, they maximize the use of hot-swappable expansion cards to connect each of the components. While for commercial computers, the reason why they tend to stay in a controlled environment is also because of their cabled computer components.
3. Industrial grade Vs. Commercial-Grade Components
Industrial computers are made from industrial-grade materials tested to ensure durability and reliability when deployed in harsh environments. Unlike commercial computers that have not been designed to survive harsh environments, industrial computers use high-quality components that have been tested to endure wide-operating temperatures. For example, industrial-grade computers chassis are made out of extruded heavy-duty metal to survive tough industrial challenges such as shock and vibration. In contrast, a commercial computer’s chassis is often time made out of thin aluminum and acrylic plastic to keep costs down.
Ruggedness and Reliability
1. Shock and vibration
Industrial applications like robotic automation and mining processes often encounter a high level of shock and vibration. Therefore, industrial computers are designed in a way to limit the potential failure caused by shock and vibrations. In order to ensure reliability, under these conditions, the best industrial computers eliminate failure points by incorporating fanless designs and using a one-piece chassis. The exterior shell is specifically built in a one-piece design to avoid additional joints and screws. These industrial-grade design techniques provide a robust structure that can even meet MIL-STD-810G qualifications in shock and vibration, which indicates a computer’s ability to be used in specific military applications.
On the other hand, commercial computers consist of many moving parts, such as cables, fans, and hard disks. The exterior chassis is made up of aluminum metal and acrylic plastic, which are not designed to withstand high levels of shock and vibrations. In fact, many aspects of a commercial computer are not suitable for shock and vibration because of common failure points.
Vibration Resistant Embedded Computer – Premio Inc
2. IP (Ingress Protection) rating
The key for rugged and reliable industrial computers is eliminating multiple failures, especially from dust and water elements. Many industrial applications require the computer to function in extremely dirty and water-logged environments; for example, automation equipment in food processing requires daily hygienic washdowns with high-power jets with special chemical agents. Therefore, industrial computers are accompanied by the level of IP protection from the exterior design (one-piece chassis), fanless cooling, and even special connectors (M12) to keep out dust and water. M12 connectors are dust and water-proof connectors, with a built-in locks in order to secure cables to a computing machine. At the same time, the fanless designs avoid the inflow of dust and foreign particles into the computer’s components because of the removal for ventilation holes that are required with active fan cooling.
Commercial computers and their use cases often times do not require IP rating. But since most commercial computers are used indoors and in dry office spaces, there is no need for IP protections.
IP67 Embedded Systems | Tightly Sealed Waterproof and Dustproof Indust – Premio Inc
3. Extreme temperatures
As mentioned before, an industrial pc utilizes a heatsink and heat pipe instead of using a fan to dissipate the heat effectively. It is also assembled from highly durable industrial-grade components that can handle a higher temperature ranging from –40⁰C up to 85⁰C, enabling operation in extreme cold and hot environments.
Commercial computers with active cooling fans can only withstand temperatures that range from 0 –35⁰C. Heat is a detrimental element for computing electronics because it can damage mission-critical components like the CPU, memory, and storage if not properly cooled. Therefore, active fans are popular cooling solutions for commercial computers to remove heat from the system itself.
Wide Temperature Range Embedded Systems – Premio Inc
4. Electromagnetic interference
(EMI)
Electromagnetic interference is a phenomenon where one electromagnetic field interferes with another in the same range of radiofrequency (RF). EMI causes degradation of the circuit and may even stop it from functioning. Industrial computer designs ensure complete isolation and prevention from the radiation from penetrating through the computer. Compliance standards like FCC and EC are common practices to ensure EMI safety and compatibility. Both industrial computers and commercial computers must meet EMI compliance and safety regulation in order to be used in a variety of applications.
5. Wide power range
Industrial computer’s power supply unit (PSU) design is completely fanless, cable-less, and wide voltage protection. The wide power range allows input ranging from 9V to 48V, accompanied by over-voltage protection (OVP) to prevent input of more than 55V and an overcurrent protection (OCP) to prevent inrush current from damaging the system. However, the commercial computer’s PSU uses an active cooling fan and cables, causing the dust and dirt to clog up the system. A bad PSU causes fire from overheating and voltage fluctuations, leading to permanent damage to the computer’s components.
6. Expansion capabilities, rich I/O ports Vs. Limited I/O ports
Industrial computers are capable of managing various data inputs that transmit data for real-time decision-making. In addition, industrial computers provide an extensive range of input/output ports to enable their expandability and capability in fulfilling industrial workloads. For example, there are serial ports, USB, PoE LAN, Video ports, DIO/GPIO, M12 ports, and much more. I/O flexibility is a key requirement for many industrial computing deployments that rely on both analog and digital connections. In contrast, commercial computers are limited in I/O but often times offer the latest in I/O ports for the best performance.
Most Popular I/O Ports for Industrial Computing and Factory Automation – Premio Inc
When Reliability Counts, Choose Industrial Computers
Industrial computers support embedded applications and can be used for 5 to 7 years due to its longevity in design. Overall, industrial computers are purpose-built for ultimate reliability and long-term use without any interruptions. As for commercial computers, their designs are based on the current trends that follow the performance as its requirement for specifications. That is why most commercial computers can be upgraded to the latest technology relatively quickly.
Commercial and Industrial Applications:
Commercial computer
Commercial and industrial computers have the same capabilities that work efficiently in different environments. However, commercial computer features active cooling fans and cable designs that require them to work in a controlled room where dust and foreign particles are less likely to interfere with the computer’s performance. For example:
Office environment
School environment
Every-day use computer
Industrial computer
1. Manufacturing and industrial automation
Industrial computers manage motion control systems for product inspection, data logging, and data analysis for improved manufacturing productivity. For example, industrial computers have increased the accuracy and efficiency of computer industry operations, usually used to automate various processes involved in motherboard PCB making.
2. Interactive kiosk
Kiosk machines are everywhere; small industrial fanless PCs power all self-service kiosks since they are compact and pretty powerful to run various kiosk applications. Mini industrial PCs improve multiple aspects of our life by delivering a seamless experience. For example, integrating small form factor industrial PCs in a self-service kiosk in the airport enable passengers to eliminate the time spent waiting in a long queue during airport check-ins. Moreover, industrial computers are equipped with high-speed ports like USB 2.0 and 3.0 to provide enormous flexibility and power many IoT sensors integrated into kiosk machines for self-service automation.
3. Automation inspection and testing equipment
Quality control applications need the combination of machine vision or digital measurement instruments in order to process information with speed and accuracy. Industrial computers with GPUs (Graphics Processing Units) enable the system to run machine inferencing at the edge without being dependent on the cloud. Industrial computers with GPUs enable the machine to perform intelligent machine vision, which ensures all measurements are precise and components are manufactured according to predetermined specifications. Additionally, Industrial PCs also help speed up the manufacturing process with greater accuracy and intelligence by running automation software for flexibility.
4. Security and surveillance
Security and surveillance solutions are often placed in harsh environments, like public transportation systems and outdoor security systems. Industrial PCs are capable of withstanding deployments in tough environments; Moreover, some industrial computers are specialized with multiple PoE ports that provide stable connections to IP cameras. Moreover, PoE allows industrial computers to deliver power and transmit video footage data on a single cable. Thus, reducing the cabling footprint of the security system while improving passenger’s safety.
5. Underground mining
Underground mining requires computers to withstand the demanding conditions of dust, wide temperature range, shock, and vibrations. Industrial computers are perfectly made for this operation. Known for their robust structure, highly critical performance, and accuracy in capturing valuable telemetry for construction and digging sites, industrial computers can quickly be deployed at a remote underground site for processing and data telemetry.
6. Military and maritime
Industrial computers are capable of surviving the harsh operating conditions of ground control operations and aboard ships in the maritime industry. They require low maintenance and long operating life that meets the MIL-STD-810G qualification in shock and vibration. Most importantly, industrial computers are engineered to be fully dust and water-resistant to operate in various military applications.
What Makes Up the Best Industrial PC?
Industrial PCs are designed and assembled to fit into industrial applications with proven reliability. Its One-piece chassis design and fanless cooling protect the computer from external debris intrusion and wide temperature environments. In addition, industrial PCs can also provide IP ratings to ensure their resistance against water ingress and dust particles. Last but not least, industrial PCs provide a wide range of input/output ports for expansion capability, making it easier to upgrade and replace parts of computers.
Industrial Computer Test and Validation process
Industrial computer manufacturers implement a comprehensive design validation process in order to ensure reliability. The purpose of a thorough design qualification process is to ensure durability, reliability and longevity of the product in design. Dedicated testing and specification measurements are held in reliable testing facilities with specialized equipment such as temperature & humidity chamber, 1500 KGF vibration tester, thermal shock ramp chamber, IR thermal sensor, signal integrity tester, and electrical tester. These tests include:
Compliance test: Electromagnetic compatibility (EMC) test for EC and FCC certifications.
Signal Measurement: Signal integrity for high-speed peripherals to ensure best design attributes
Stress Test: Observe results when operating beyond the normal standard or meeting maximum specification
Functional Test: Basic I/O functional test, boot up test, OS, power protection, power consumption, performance test, full loading test
BIOS setup test: To ensure the system properly detects, configures settings, and initializes all functions and devices
Compatibility test: To ensure CPUs, DIMMs, display cards, and other peripherals are compatible with the system
Environmental Test: Thermal test including four corners, operating and non-operating, booting test, shock & vibration test, sealing for IP rating, and thermal shock test
Why Premio?
Premio has been designing and manufacturing high-quality industrial-grade PCs for over 30 years, offering a wide variety of industrial PCs manufactured with high-quality components. Premio has successfully evolved into a full-service technology company specializing in top-notch computing designs that help customers overcome the greatest challenge in industrial applications. If you need assistance finding the best industrial PC, don’t hesitate to contact us. One of our industrial computing professionals will assist you in finding a computing solution for your needs.