At PSB GmbH, we understand the unique demands placed on automation PCs required to operate continuously, around the clock. Combining over three decades of engineering expertise with a deep commitment to customer-specific solutions, we deliver industrial PCs that set the benchmark for reliability and customization. Our in-house development teams work closely with clients to design systems optimized for 24/7 operation across varied industrial and medical applications, including challenging environments requiring enhanced temperature resilience and advanced protection standards. Each solution goes beyond stock offerings, providing tailored configurations and extensive testing—such as burn-in procedures—to guarantee stable long-term performance. Drawing on a robust, manufacturer-neutral approach, we ensure that the hardware selected always aligns perfectly with the individual project’s requirements. Our focus on precision engineering and flexible production practices underlines our dedication to supporting complex automation needs seamlessly and dependably.
What Is a 24/7 Automation PC?
A 24/7 automation PC is a specialized industrial PC (IPC) designed specifically for continuous use in automation environments. Unlike standard consumer computers, these PCs are engineered to operate reliably without interruption, supporting critical manufacturing, monitoring, or process control applications that require durability and robust performance. Industrial PCs for automation often feature ruggedized enclosures, advanced thermal management, and comprehensive redundancy systems to ensure reliability around the clock.
Key Characteristics
- Continuous operation: Built for non-stop performance 24 hours a day, 7 days a week.
- Maintenance-free design: Utilizes passive cooling and solid-state components to minimize servicing needs.
- Robust construction: Resistant to dust, moisture, vibration, and temperature fluctuations.
- Failover options: Often includes redundant power supplies and storage for uninterrupted production.
Why 24/7 Operation Matters in Industrial Automation
Reliability is non-negotiable in industrial automation. Downtime can cost millions in lost revenue and disrupt entire supply chains. This is why devices like a continuous operation PC or an uninterrupted production PC are critical. These platforms are specifically built to support machine tending, remote monitoring, and automated workflows with no compromise in performance or uptime.
Benefits of Continuous Use
- Uninterrupted production: Eliminates costly downtimes and maintains process continuity.
- Consistent quality: Supports quality control by ensuring systems are always operational.
- Reduced manual intervention: Enables remote management and monitoring, freeing up human resources for more complex tasks.
For industries that depend on constant processing—such as pharmaceuticals, energy, and medical technology—a reliable industrial PC in medical technology ensures both operational efficiency and compliance with stringent safety regulations.
Key Features of True 24/7 Automation PCs
Choosing the right 24/7 automation PC requires careful evaluation of both hardware and environmental factors. Below are essential features to ensure long-term performance:
1. Robustness and Durability
- Industrial-grade components engineered for harsh environments
- Shock- and vibration-resistant housing
- Wide temperature range support (often -20°C to +60°C or more)
2. Passive Cooling & Advanced Thermal Management
- Fanless designs for maintenance-free operation
- Optimized thermal pathways to prevent overheating
Example: In food and beverage processing, where particulate matter and moisture pose risks, passive cooling eliminates fan failures and reduces maintenance intervals.
3. Redundancy & Remote Monitoring
- Redundant power supplies and drives for failover
- Integrated remote monitoring for proactive maintenance
Explore maintenance strategies for servers in continuous operation for best practices on maximizing uptime with redundancy.
4. Modularity and Expandability
- Optional I/O for supporting a range of sensors and actuators
- Easy upgrade paths to adapt to evolving automation needs
Common Applications and Industry Use Cases
24/7 automation PCs are indispensable across many sectors where reliability and durability are paramount:
- Manufacturing Automation: Supports machine tending, process control, and quality assurance systems.
- Critical Infrastructure: Monitors utilities, energy grids, and transport systems requiring zero downtime.
- Logistics & Warehousing: Enables automated tracking, inventory management, and conveyor control under constant operation.
- Medical Technology: Forms the backbone of life-supporting devices and diagnostic systems with continuous uptime demands, as detailed in this article on IPCs in medical technology.
- Mobile Workstations: For high-mix, low-volume production operations, industrial mobile workstations ensure flexible and robust performance on the factory floor.
Real-World Example: Machine Tending in Automotive Plants
Automotive facilities require robust automation hardware to oversee robotic arms, CNCs, and vision inspection systems. An industrial PC with passive cooling and high redundancy ensures uninterrupted workflows, even during three-shift operations, thus reinforcing the importance of a true continuous operation PC.
How to Select the Right 24/7 Automation PC for Your Needs
Selecting the optimal industrial PC for automation involves more than just comparing specifications. Follow this actionable decision checklist to avoid common pitfalls:
Decision Checklist
- Define the environmental conditions: Assess dust, temperature, humidity, and vibration levels the PC will face.
- Specify I/O and control requirements: Determine the specific device connections, communication protocols, and peripheral needs.
- Evaluate redundancy needs: For critical systems, ensure redundant power and storage are included for failover during hardware faults.
- Review certification requirements: Depending on your industry, ensure compliance (e.g., medical, food-grade) is met.
- Plan for future expandability: Choose modular configurations to accommodate changes in production scale or process automation upgrades.
- Consider the physical installation: Some applications may require a mobile rack or modular 19-inch case for server mobility and protection.
Avoiding Common Pitfalls
- Do not use office or consumer PCs—they lack industrial-grade robustness and thermal management.
- Don’t neglect redundancy; a single point of failure can halt an entire line.
- Always factor in total cost of ownership, not just upfront price.
Maintenance, Monitoring, and Longevity Tips
Maximizing the service life and operational reliability of your maintenance-free industrial computer is critical for uninterrupted production. Here’s how:
1. Proactive Remote Monitoring
- Use remote tools to track performance, temperature, and errors in real time and schedule maintenance before failures occur.
- Leverage smart diagnostics for predictive maintenance to further reduce intervention and downtime.
2. Environmental Considerations
- Ensure installations are protected from dust and liquids—as fanless designs prevent clogging, they do not negate the need for proper enclosure selection.
- Implement surge protection and backup power to guard against grid instabilities.
3. Hardware Longevity Strategies
- Choose solid-state drives (SSD) over hard drives where possible, as SSDs better tolerate vibration and rapid cycling.
- Opt for memory and processors rated for industrial temperature ranges for predictable performance over years of 24/7 use.
- Schedule periodic firmware and security updates to protect against vulnerabilities, especially with remote monitoring capabilities.
Frequently Asked Questions
What makes a PC suitable for 24/7 operation?
A PC suitable for 24/7 operation integrates industrial-grade hardware, passive cooling, redundancy, and advanced thermal management. It prioritizes uninterrupted production and maintenance-free operation, setting it apart from standard office computers.
What industries benefit most from 24/7 automation PCs?
Industries such as manufacturing, medical technology, logistics, energy, and any sector relying on continuous use of monitoring or control systems benefit significantly. Learn more about the applications in modern industrial automation.
How long can a 24/7 automation PC last?
With proper selection and maintenance, an industrial PC for automation can last 7-10 years or more, thanks to durable components, passive cooling, and maintenance-free designs.
How do I ensure the longest possible uptime?
Focus on redundancy, environmental protection, and real-time remote monitoring. Best practices are discussed in detail in this guide to server selection and maintenance for continuous operation.
In an era where continuous, uninterrupted automation is essential, investing in the right PC solution is critical to long-term operational success. PSB GmbH’s experience in developing and producing custom-configured, industrial-grade automation PCs has repeatedly demonstrated the value of technical rigor and collaborative engineering. Our commitment to thorough qualification, ongoing support, and rigorous testing reflects our priority: ensuring our clients’ systems function reliably under the most demanding conditions. By consistently delivering solutions that are both robust and adaptable, we enable our partners to focus on their core processes with confidence. Looking ahead, we remain dedicated to evolving with technological advances and supporting the ever-changing requirements of industrial automation. Our team stands ready to address new challenges with the same steadfast commitment to quality and client satisfaction that has defined PSB for over 30 years.
