When to Use Industrial Computer？

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:   

1. Compliance test: Electromagnetic compatibility (EMC) test for EC and FCC certifications.   

    

2. Signal Measurement: Signal integrity for high-speed peripherals to ensure best design attributes  

    

3. Stress Test: Observe results when operating beyond the normal standard or meeting maximum specification  

    

4. Functional Test: Basic I/O functional test, boot up test, OS, power protection, power consumption, performance test, full loading test  

    

5. BIOS setup test: To ensure the system properly detects, configures settings, and initializes all functions and devices   

    

6. Compatibility test: To ensure CPUs, DIMMs, display cards, and other peripherals are compatible with the system  

    

7. 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. 

Type of computer intended for industrial purposes

An industrial PC is a computer intended for industrial purposes (production of goods and services), with a form factor between a nettop and a server rack. Industrial PCs have higher dependability and precision standards, and are generally more expensive than consumer electronics. They often use complex instruction sets, such as x86, where reduced instruction sets such as ARM would otherwise be used.

History

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IBM released the 5531 Industrial Computer in 1984,[1] arguably the first "industrial PC". The IBM 7531, an industrial version of the IBM AT PC was released May 21, 1985.[2] Industrial Computer Source first offered the 6531 Industrial Computer[3] in 1985. This was a proprietary 4U rackmount industrial computer based on a clone IBM PC motherboard.

Applications

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Industrial PCs are primarily used for process control and/or data acquisition. In some cases, an industrial PC is simply used as a front-end to another control computer in a distributed processing environment. Software can be custom written for a particular application or an off-the-shelf package such as TwinCAT, Wonder Ware, Labtech Notebook or LabView can be used to provide a base level of programming. Analog Devices got exclusive sales for OEM European industrial market and provided MACSYM 120 combined IBM 5531 and MACBASIC a multitasking basic running on C/CPM from Digital Research. Analog and digital I/O cards plugged inside PC and/or extension rack made MAC120 as one of the most powerful and easy to use controller for plant applications at this date. An application may simply require the I/O such as the serial port offered by the motherboard. In other cases, expansion cards are installed to provide analog and digital I/O, specific machine interface, expanded communications ports, and so forth, as required by the application.

Industrial PCs offer different features than consumer PCs in terms of reliability, compatibility, expansion options and long-term supply.

Industrial PCs are typically characterized by being manufactured in lower volumes than home or office PCs. A common category of industrial PC is the 19-inch rackmount form factor. Industrial PCs typically cost considerably more than comparable office style computers with similar performance. Single-board computers and back planes are used primarily in industrial PC systems. However, the majority of industrial PCs are manufactured with COTS motherboards.

A subset of industrial PCs is the Panel PC where a display, typically an LCD, is incorporated into the same enclosure as the motherboard and other electronics. These are typically panel mounted and often incorporate touch screens for user interaction. They are offered in low cost versions with no environmental sealing, heavier duty models sealed to IP67 standards to be waterproof at the front panel and including models which are explosion proof for installation into hazardous environments.

Construction and features

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Virtually all industrial PCs share an underlying design philosophy of providing a controlled environment for the installed electronics to survive the rigors of the plant floor. The electronic components themselves may be selected for their ability to withstand higher and lower operating temperatures than typical commercial components.

• Heavier metal construction as compared to the typical office non-rugged computer
• Enclosure form factor that includes provision for mounting into the surrounding environment (19" rack, wall mount, panel mount, etc.)
• Additional cooling with air filtering[4][5]
• Wider operating temperature range than normal PCs, with the widest temperature ranges being -40 to 75°C
• Alternative cooling methods such as forced air, liquid, and conduction
• Expansion card retention and support
• Enhanced EMI filtering and gasket
• Enhanced environmental protection such as dust proof, water spray or immersion proof, etc.
• Sealed MIL-SPEC or Circular-MIL connectors
• More robust controls and features
• Higher grade power supply
• Controlled access to the controls through the use of locking doors
• Controlled access to the I/O through the use of access covers
• Inclusion of a watchdog timer to reset the system automatically in case of software lock-up

See also

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References

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