Industrial Computers, Keyboards, Monitors, Mice

Industrial computers have finally reached a performance level that makes software move at a desirable speed.  We have combined control, I/O, motion, and machine vision all on one computer with adequate response times.  We have found that Windows 2000, Pentium 4 at 3 GHz, hyper-threading, 512 MB RAM, 7200 RPM hard drive, PCI bus, and AGP graphics provides a fast enough platform to replace many PLCs.  Having a control engine and operator interface on the computer connected to remote, distributed I/O is now a viable option.  However, for large or fast applications we still prefer to use a PLC and computer combination. 

For an additional power boost check out Symmetrical Multi Processors.  Although we do use multi-processor computers, we do not use over clocking or other techniques to boost computer speeds beyond their intended use.  However, a lot of the ideas and technologies these "extreme" groups develop, such as cooling, are very useful in industrial systems.  Who would not want their CPU, drives, and other equipment to run 20 to 30 degrees cooler?  It means greater reliability and longer life.  

One comment we hear a lot is "but my desktop computer crashes all the time".   Crashes happen on computers that are not maintained, where users are overloading them, installing and uninstalling a lot of different applications, etc.  If PLCs were used like desktop computers, PLCs would crash too.  The point being is if you set up a computer to perform one task (like a PLC) then crashes are unlikely.  We think that Microsoft's new .NET platform will eventually eliminate many of these types of problems. 

Hard Drives, Backups, Disk Mirroring, RAID

Many people's biggest concern is the hard drive failing.  While ten years ago this was definitely true, hard drives are much more reliable today.  The MTBF (Mean Time Between Failure) exceeds 100 years (1 million hours) on some hard drives and most hard drives come with a three or five year warranty. 

If your computer is connected to a network then it is easy to back up your critical files to a server.  In fact you can even go without a hard drive on your computer and only use the file server (hence the name "thin" client). 

Arco Data Protection Systems makes several products that allow disk mirroring / RAID 1.  This is where there are two hard drives and the same data is written to both drives.  If one drive fails then the controller automatically switches to the good drive.  This is good for critical systems or for systems where the user does not do regular backups.  Solutions start at $250 for the RAID PCI controller plus $150 for a second hard drive. 

Arco also sells solutions for removable hard drives.  If you are concerned about a major disaster destroying the building, computer and hard drives, then buy four (or more) hard drives, keep two installed in the computer, and keep two at home (or off site), and swap one drive a day.  For example, drives 1 and 2 are installed in the computer, drives 3 and 4 are at home.  Before leaving for work, get drive 3 to take to work.  Before leaving work, remove drive 1, insert drive 3.  Overnight, the Arco software automatically updates drive 3 to be a copy of drive 2.  Take drive 1 home.  The next morning take drive 4 to work (drive 1 stays at home), when leaving work remove drive 2, insert drive 4.  With a high performance 100 GB hard drive only costing $150 this solution now makes sense for many applications.  Although hard drives are much better at sustaining shock and vibration, we still recommend some padding when transporting hard drives.  And keep them out of the sun, heat, and cold. 

Many motherboards are starting to include built-in RAID controllers. 

Note that there are websites that allow you to backup your data to their website in the event of catastrophic failure also.  However, many of these websites have gone out of business and some people have had concerns about getting their data back. 

For some systems you might want more than RAID 1.  We recommend reviewing Adaptec Raid Products to see additional options for critical systems.   

The Power of Ethernet

This "ethernet thing" is becoming very powerful.  You can connect your Keyboard, Video, Mouse (KVM) over ethernet so that the process computer could actually be a "blade" computer mounted in a rack in some environmentally controlled room.  You simply run the ethernet out to the machine where the keyboard, monitor, and mouse are located.  But what about all the devices that you have to connect to, you ask?  Most I/O can now work over ethernet as well as serial communications.  So for probably close to 80% of the applications you can remove the computer from the factory floor, install them all in a rack, and simply mount ethernet switches out in the environmentally tough area. 

The only problem with this solution at the moment is that it costs about $1,000 per computer.  But expect this price to drop to about $250 in a couple of years. 

Frequently Asked Questions (FAQs)

Are industrial computers worth the higher cost?  It is true that industrial computers are often two to three times the cost of office grade computers.  In some cases, such as limited space, you do not have an option and must use an industrial computer.  The biggest drawback to industrial computers is that since they are replaced as often as office computers (typically every three years) your costs are double or triple.  Two tricks can help you use office computers.  One - use an industrial monitor, mouse, keyboard, office computer and relocate the computer in a nicer environment.  Use monitor and keyboard extenders, Ethernet, and other tricks to extend the distance between the computer and industrial environment.  Second, use an industrial enclosure.   NOTE that regardless of whether we use an office or industrial computer we still use items to protect the computer such as surge suppression, noise filtering, vibration isolation, UPS, cooling etc.  

Industrial Computers Related Links

• Servers  
• Industrial networking  
• Operator Interfaces  many computer monitors are listed under operator interfaces 
• Industrial Enclosures  put an office computer out in the harsh environment 
• Visual Basic and C# for factory & laboratory automation  
• Computer - PLC communications
• Microsoft .NET

Industrial Computer Links

• Advantech  
• Ann Arbor Technologies
• Armor Link
• Beckhoff 
• Chassis Plans 
• Comark  
• Contec 
• CTI Electronics 

• Cyber Research   

• Daisy Data  
• Dap Technologies -- rugged, mobile computers

• Datalux -- mobile and industrial displays, keyboards, "brick" computers

• Dolch  

• Dynamic Displays -- medical, industrial, and military displays

• Earth LCD 
• Electronic Keyboards 
• EG Technology -- industrial computers, enclosures, peripherals
• Fastpoint Technologies -- industrial light pens for applications that are too harsh and touch screens can not be used.  They also sell industrial monitors and touch screens. 
• Formosa Industrial Computing  
• Hope Industrial Systems -- low cost, industrial, flat, panel mount, LCD monitors
• Industrial PC
• IICON 
• Kontron  
• Man & Machine 

• MGR Industries -- industrial encrypted keypads, keyboards, joysticks

• Mintronix -- these are "light industrial" (not NEMA) rated computers and monitors so their prices are lower

• Nortech Engineering -- Displays, panel PCs, shoebox PCs, industrial computer cabinets, keyboards

• PC Power & Cooling -- personal computer cases, redundant power supplies, cooling devices, heat alarms

• Planar Systems 
• Small PC -- rugged computers for small spaces
• Stealth Computer -- PCs, monitors, peripherals
• Texas Micro
• Texas Industrial Peripherals  
• Touch Screens Inc. 
• Touch Controls  
• Touch Systems  
• Xycom 

We try to offer a fair and balanced opinion on every page of our website.  We would appreciate more information from other industrial computer users to express their opinions which we will then incorporate.  If you have questions or comments please post them on our message board (see button in left hand column) so that others can read and benefit.