In extreme industrial environments, choosing the right computer can make the difference between smooth operations and costly downtime. Harsh conditions like high heat, sub-zero cold, water exposure, dust, and heavy vibration can quickly destroy standard office-grade PCs.
Downtime in these environments is not just inconvenient – it’s expensive. In the automotive industry, unplanned shutdowns can cost as much as $2.3 million per hour. In oil and gas facilities, operations lose up to 32 hours per month due to system failures. These losses multiply across sectors where every minute of inactivity means lost output, spoiled goods, or expensive restarts.
The table below shows how unplanned downtime impacts different types of manufacturing and industrial operations:
Given the scale of these losses, selecting the right industrial computer is critical to system uptime. Unlike traditional desktops, rugged industrial computers are engineered for high durability. They can withstand vibration, dust, water, and extreme temperatures, making them essential for maintaining operational continuity in the world’s most challenging environments.
“Extreme” or harsh environments can refer to any setting that challenges electronics beyond normal climate-controlled conditions.
This can include temperature extremes (extreme cold, or scorching heat often found in deserts or near industrial furnaces), moisture and water exposure (rain, high humidity, washdowns, or full immersion), dust and dirt (from fine powders to gritty sand), mechanical stress (continuous shock and vibration from machinery or vehicles), and even corrosive or explosive atmospheres (salt spray at sea, chemical fumes, or flammable gases).
In practical terms, a “harsh environment” could be an outdoor oil rig battered by weather, a food processing plant with daily high-pressure washdowns, a mining site filled with dust and blasts, or a military vehicle subject to severe shocks. Understanding the specific environmental stresses of your application is the first step in choosing a suitable industrial computer.
Rugged computer standards like MIL-STD- 167 (Vibration resistance of shipboard equipment) enumerate many of these conditions, from temperature shock and humidity to salt fog corrosion and explosive gas environments, underscoring the wide range of hazards a computer might face in the field.
When evaluating industrial computers for extreme environments, keep the following key criteria in mind:
Ensure the PC can handle the temperature lows and highs of your environment. Many rugged designs offer extended temperature ranges (for example, -40 °C to 70 °C on our All-Weather line) thanks to fanless cooling and industrial components. Check that the operating range (while powered) covers your needs, not just storage temperature. Extreme cold may require heating elements, while extreme heat might necessitate specialized cooling or throttling protection.
Verify the enclosure’s sealing against dust and water. IP codes define levels of protection – for instance, an IP67 rating means a device is completely dust-tight and can withstand immersion in 1 meter of water for 30 minutes. NEMA ratings (a standard in North America) similarly indicate enclosure protection.
For example, NEMA 4X enclosures not only keep out dust and water like IP66 does but also provide corrosion resistance against cleaning chemicals. In wet, dirty, or washdown settings, look for high IP/NEMA ratings such as IP65/66/67 or NEMA 4/4X/6 to ensure the computer will withstand rain, splashes, or even full washdown cleaning processes.
Longevity and support are key: industrial computers often must operate failure-free for years, and companies such as VarTech Systems offer long product life cycles and support for any replacement parts or repairs, which can be just as important as the initial specifications.
Maintenance and expandability are also considerations; you may want to think about whether the system will be easily serviceable (such as having handy dust filters or modular components), and if you might need to upgrade components (more I/O, memory, etc.) at some point.
Also, evaluate power input requirements and capabilities, including any software/OS restrictions. Consider if you require dual power supplies or the ability to gracefully shut down when on UPS. Verify the hardware capabilities for the desired OS and industrial software.
Industrial computers must endure physical shocks such as impact, drops, and constant vibration if mounted on machinery or vehicles. Look for devices tested to military or industrial ruggedness standards such as MIL-STD-810 vibration and shock tests to ensure they can handle real-world abuse.
Fanless, solid-state designs are preferred for high-vibration environments. Rugged PCs often use reinforced mounting brackets, dampeners, and robust connectors so that bumps and jolts won’t interrupt operation.
Consider how and where the computer will be installed. Options include panel-mount PCs that fit into control panel cutouts, rack-mount servers for racks of varying sizes, wall or VESA mounts, and DIN-rail or clamp mounts for small form factor PCs.
The mounting style should support the environment’s needs. For example, a vibration-prone vehicle might require a shock-isolated mount, whereas a food processing facility needs a fully sealed stainless-steel build or a panel mount computer with a stainless-steel faceplate to meet hygiene needs.
Ensure the chassis size and configuration such as fanless box or all-in-one panel PC, fit your space constraints and allow for secure installation in the intended location.
In extreme and hazardous environments, regulatory certifications are crucial. For instance, in environments with flammable gases or dust such as oil refineries and chemical plants, computers may need hazardous location certifications like ATEX or Class I Division 2.
ATEX, derived from “Atmosphères Explosibles”, is the European Union’s directive ensuring equipment won’t ignite within explosive atmospheres. The North American equivalent is the Class/Division system – a Class I Division 2 (C1D2) rating indicates the device is safe in areas where flammable gas is normally contained but could escape in abnormal conditions. Verify any required safety certifications such as ATEX, C1D2/C1D1, or IECEx if the computer operates in hazardous areas. The differences between each of them are best illustrated by this table:
Additionally, military or aerospace use, MIL-STD compliance and EMI/EMC certifications, such as MIL-STD-461 for electromagnetic interference, might be necessary. Industry-specific standards such as marine electronics certifications and railway standard EN50155 for rolling stock could also apply. Always check that the computer meets all applicable standards for your industry and location.
Different industries tend to face environmental challenges. Below is a summary of common conditions in various sectors and what to look for in an industrial computer for each:
In each of these areas, industrial computers act as control and monitoring centers for essential processes. In factories, they collect sensor data and control automation systems. They are found in vehicles for navigation, surveillance, controlling on-board systems, and monitoring performance.
In agriculture and urban infrastructure, industrial systems are outdoors year-round, driving irrigation systems, traffic controls, and remote security under harsh conditions of moisture, dust, and direct sun exposure.
In conclusion, choosing the right industrial computer for extreme environments requires ensuring that the device’s design and certifications are designed to suit the challenges facing the environment in question.
With careful consideration of temperature ratings, ingress protection, shock/vibration tolerance, mounting style, and any necessary certifications, you can find options that will not only work but exceed expectations in conditions where the average computer would quickly fail.
In the end, it is worth speaking to the manufacturer or an industrial computing professional who can verify that a model has been properly vetted in such conditions.
With the appropriate rugged computer in place, you will safeguard your operations against environmental disruptions and ensure continuous, safe performance even in the harshest of conditions. Working with an experienced provider like VarTech Systems can help you navigate these decisions, as they offer a range of ruggedized computers and HMIs engineered for environments from oil fields to factory floors.
By following the steps outlined above and leveraging expert guidance when needed, such as through our experienced Project Managers with an average 15 years of tenure, you can confidently choose an industrial computer that meets the demands of your extreme environment and keeps your critical systems running smoothly for years to come.
At VarTech Systems, our Project Managers—with an average of 15+ years of industry experience—are ready to customize a computer, monitor, or HMI workstation solution to meet your needs. Drawing from extensive backgrounds in manufacturing, military, oil and gas, and marine applications, they provide expert guidance throughout your project journey.
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Based in Clemmons, North Carolina, VarTech Systems Inc. engineers and builds custom industrial and rugged computers, monitors, and HMIs.
