Industrial PC in Mechanical Engineering: Selection & Trends

As industrial automation advances, the role of PC-based solutions in mechanical engineering continues to grow. At PSB GmbH, we recognize the critical demands machine builders place on reliability, adaptability, and integration within challenging environments. The selection and deployment of industrial PCs must account for thermal management, ingress protection, and seamless compatibility with diverse control architectures. Drawing on more than three decades of engineering experience, our team delivers tailored systems engineered to withstand harsh industrial conditions and complex requirements. We approach every project as a unique technical challenge, combining flexibility and robust design with the precision our customers expect. The result is a solution that not only fits the application, but sets new standards for performance and longevity.

What is an Industrial PC? Definition and Differences from Office PCs

An Industrial PC (IPC) is a high-performance computer system specifically engineered for use in demanding industrial settings. Unlike conventional office PCs, industrial computers offer superior robustness, reliability, and a wide range of connectivity and integration options for machinery. In manufacturing and engineering, the requirements for automation, machine control, and process monitoring demand solutions that can endure harsh environmental conditions such as dust, extreme temperatures, vibration, and electrical noise.

• Robustness: Rugged housings, enhanced shock protection, extended temperature tolerance
• Long-term availability: Components with long lifespans and predictable spare-part roadmaps
• Custom form factors: Ranging from compact box PCs to large panel PCs suitable for control stations
• Deterministic real-time capabilities: For time-critical control tasks that standard PCs cannot handle

Typical differences between industrial PCs and office computers include:

Requirements for Industrial PCs in Mechanical Engineering

Industrial computers used in machine building must meet high standards for robustness, safety, and reliability to guarantee uninterrupted operation and minimal downtime.
Important requirements include:

• Environmental resistance: Protection from dust, humidity, vibration, and extreme temperatures (–20°C to +60°C or higher)
• Reliability: 24/7 continuous operation with low failure rates
• Compliance with industry standards: EMC, CE, IP65/67, as required for specific applications
• Flexibility: Easy integration into control cabinets, operator panels, or directly onto machines
• Maintenance: Remote maintenance, hot-swappable components, monitoring of system parameters (e.g., temperature, fan)
• Scalability: Modular performance upgrades for different applications
• Cybersecurity: Hardware and software features to protect equipment and data from unauthorized access

Types of Industrial PCs: Box PC, Panel PC, Embedded Solutions

Box PC

Box PCs are compact, flexible systems, usually without integrated displays, that can be mounted inside control cabinets or directly on machines. With a variety of interfaces (Ethernet, USB, serial, fieldbus systems), box PCs are ideal as central control units in automation and for data acquisition.

• Example: Using a box PC to collect machine data and send it to a central MES system for further processing.
• Applications: Manufacturing, robotics, process industry

Panel PC

Panel PCs integrate an industrial touch display and a powerful computer in one system. They are commonly used as operator interfaces (HMI) for machine operation, monitoring, and parameter adjustments. Rugged front panels (e.g., IP65-protected) enable installation directly on machinery or as part of control panels.

• Example: Panel PC with capacitive touch for controlling a packaging machine, providing instant feedback and process visualization for operators.
• Applications: Packaging machines, food processing, assembly cells

Embedded PC

Embedded PCs are highly integrated, energy-efficient computers designed for specific tasks, often focusing on low power consumption and compact housings. They are used in edge computing, as IoT gateways, or for real-time data processing directly on or within the machine.

• Example: Embedded PC as a data logger for vibration analysis in predictive maintenance.
• Applications: Condition monitoring, IoT, mobile robotics

Integration in Machines and Production Facilities

The integration of industrial PCs into machines and production lines is a key driver of automation and increased productivity. IPCs enable the connection of sensors, drives, controllers, and supervisory systems in modern Industry 4.0 environments.

Methods of Integration

• Direct control: PLC replacement or supplement for complex control tasks (hardware or software PLCs)
• Data hubs: Collection and preprocessing of production and process data (e.g., for quality assurance or predictive maintenance)
• Interfaces: Extensive connectivity with fieldbus systems (e.g., PROFIBUS, EtherCAT), IoT protocols (MQTT, OPC UA), and traditional industrial interfaces (RS232/422/485)
• Operator interfaces: Providing clear HMI panels via Panel PCs, improving usability and process transparency

Example: Digital Retrofit in Existing Plants

By integrating box PCs and embedded PCs, older machines can be retrofitted to enable connectivity and automation (digital retrofit). IoT gateways collect sensor data and make it available for remote monitoring and analytics, making factories “smarter” without major renovations.

Application Examples: From Machine Control to Data Acquisition

1. Machine Control: Panel PCs and embedded PCs control packaging machines in real time, managing recipe changes and format adjustments with user-friendly HMIs.
2. Image Processing: High-performance box PCs process large image datasets for quality inspection and sorting in automated assembly lines.
3. Process Monitoring: Embedded PCs record temperature, vibration, and cycle times on production machines and relay anomalies to maintenance teams.
4. Building Automation: Industrial PCs manage HVAC, automatic doors, and lighting, integrating with building management systems (BMS) via BACnet or Modbus.
5. IoT Edge Computing: Embedded PCs serve as edge devices, aggregating data from sensors and transmitting it securely to cloud services or MES/SCADA systems.

Selection Criteria: Performance, Robustness, Connectivity, and Maintenance

Performance

Industrial PCs offer scalable computing power, from energy-saving Atom CPUs to high-performance Intel Core and Xeon processors. The choice depends on the application, such as simple control tasks or complex image processing. Always consider expandability (RAM, storage, I/O cards).

Robustness and Reliability

Look for features such as fanless cooling, industrial-grade components, IP protection ratings, and vibration-resistant mounting to ensure safe and continuous operation (24/7).

Connectivity

• Classic I/O: Digital/analog interfaces, RS232/485 serial ports, CAN bus
• Networking: Multiple Gigabit Ethernet ports for redundant connections
• Fieldbus: Support for PROFIBUS, Modbus, EtherCAT, PROFINET
• IoT/Industry 4.0: MQTT, OPC UA, wireless (Wi-Fi, LTE, 5G)

Maintenance

• Remote diagnostics: Tools for monitoring system parameters and troubleshooting remotely
• Modularity: Hot-swappable drives, expansion cards, field-replaceable fans and power supplies
• Long-term service support: Availability of updates, spare parts, and technical assistance for several years

Checklist for Selecting an Industrial PC

• Is the required computational power sufficient for the application?
• What environmental conditions must be tolerated?
• Which industrial communication protocols (fieldbus, IoT) are essential?
• How easy is maintenance and upgrading?
• Are industry certifications (CE, UL, IP) available?
• Is reliable continuous operation possible?

Trends and Innovations: Industry 4.0, IoT, and AI in Machine Building

The future of machine building is shaped by the integration of industrial PCs with Industry 4.0 concepts and the Internet of Things (IoT). Focus areas include digitalization, data-driven process optimization, and intelligent automation using artificial intelligence (AI).

Key Trends

• IoT and Edge Computing: Decentralized embedded PCs process data close to the machine, reducing latency for real-time automation and analysis.
• AI Integration: Integrated AI/ML accelerators enable predictive maintenance, quality control, and process optimization directly on the industrial PC.
• Enhanced Cybersecurity: Hardware-based security modules (TPM, secure boot) and frequent software updates protect against cyber threats.
• Modularization & Scalability: Flexible platforms support upgrades and adaptation to changing production needs.
• Visualization: High-resolution touch panel PCs enhance HMIs, with growing support for gesture and voice controls.
• Cloud Integration: Modern industrial PCs securely connect to the cloud for data storage, analytics, and remote services.

Example: An embedded PC with integrated GPU processes camera feeds on the production line for real-time anomaly detection using deep learning, improving quality assurance and reducing waste.

FAQ: Frequently Asked Questions about Industrial PCs in Machine Building

1. How long does an industrial PC last compared to an office PC?
   Industrial PCs are designed for long-term use—often 10 years or more in 24/7 continuous operation, thanks to their industrial-grade components and robust design.
2. Can a standard PC be used for machine control?
   While technically possible for simple visualization, only industrial PCs offer the required robustness, real-time capabilities, and certifications necessary for safe and reliable machine control.
3. How do I update or maintain my industrial PC?
   Many systems support remote diagnostics, modular upgrades, and easy part replacement during operation. Look for suppliers with long support cycles and reliable spare part availability.
4. Is an industrial PC compatible with IoT and cloud services?
   Modern IPCs support native IoT protocols (OPC UA, MQTT), edge computing, and secure cloud connections for digitalization and Industry 4.0 projects.
5. When is a panel PC preferable to a box PC?
   Panel PCs are best for operator interfaces (HMI) requiring direct input and visualization at the machine. Box PCs work better for “headless” central operations.

The importance of carefully selecting and adapting industrial PCs for machine building lies in achieving consistent performance, safety, and future-proofing amid demanding environments. PSB GmbH’s extensive experience in developing custom-fit solutions enables our partners to meet evolving requirements, from extended temperature operation to compliance with strict protection standards. Our commitment to thorough burn-in testing, independent manufacturer-neutral sourcing, and scalable production ensures dependable systems for every project scope. We continue to invest in our engineering expertise and global partnerships to remain at the forefront of industrial hardware innovation. Looking ahead, we are prepared to help drive progress in mechanical engineering with solutions that combine proven durability with adaptability for tomorrow’s challenges.