Top 10 Industrial Control Computer Brand & Manufacturers

What is an Industrial Control Computer?

An industrial control computer, also known as an industrial PC or IPC, is a specialized computer designed to operate in industrial environments and perform control functions. It is used to manage and monitor industrial processes, machinery, and automation systems. These computers are built to withstand harsh conditions such as extreme temperatures, dust, vibration, and electromagnetic interference that are commonly found in industrial settings.

History of Industrial Control Computer

The concept of using computers for industrial control dates back to the mid - 20th century. Initially, large mainframe computers were used in some industrial processes, but they were expensive and not very suitable for the factory floor. As microprocessor technology advanced in the 1970s and 1980s, smaller and more affordable industrial control computers began to emerge. These early IPCs were used mainly for simple process control and data logging. Over time, with the development of more powerful processors, advanced operating systems, and rugged hardware designs, industrial control computers have become more versatile and capable of handling complex automation and control tasks in a wide range of industries.

Purpose of Industrial Control Computer

• Process Control: In manufacturing plants, industrial control computers are used to regulate and optimize industrial processes. For example, in a chemical plant, they can control the flow of chemicals, the temperature of reactors, and the pressure in pipelines. By continuously monitoring and adjusting these parameters, they ensure the quality and efficiency of the production process.
• Machine Automation: IPCs are used to automate machinery such as CNC (Computer Numerical Control) machines, robotic arms, and assembly lines. They send precise instructions to the machines, enabling them to perform complex tasks with high accuracy and repeatability. This not only increases productivity but also reduces the risk of human error.
• Data Acquisition and Monitoring: These computers collect data from sensors and other devices in the industrial environment. The data can include temperature, pressure, flow rate, vibration levels, and more. By analyzing this data in real - time, operators can detect problems early, predict maintenance needs, and make informed decisions to improve overall system performance.

Principle of Industrial Control Computer

Industrial control computers operate based on the principles of computer - based control systems. They have input/output (I/O) interfaces that allow them to communicate with sensors, actuators, and other industrial devices. The computer's central processing unit (CPU) processes the data received from the inputs according to pre - programmed algorithms and control logic. It then sends output signals to the actuators to control the industrial process. The software running on the IPC, which can range from simple ladder logic programs to complex custom - developed applications, determines the specific control actions and decision - making processes.

Features of Industrial Control Computer

• Rugged Design: Industrial control computers are built with robust enclosures to protect the internal components from dust, moisture, and mechanical shocks. The components are often mounted on shock - absorbing materials, and the enclosures may have features such as sealed connectors and cooling fans designed for industrial environments.
• Expansion Capability: They typically have a wide range of expansion slots and ports to connect to various industrial devices. This allows for easy integration of additional sensors, actuators, communication modules, and other peripherals as the needs of the industrial process change or expand.
• Real - time Operation: Many industrial control applications require real - time processing of data and immediate response to events. Industrial control computers are designed to handle real - time tasks efficiently, ensuring that critical control functions are executed without significant delays.
• High Reliability: These computers use reliable components and often have redundant features such as dual power supplies or backup storage systems. The operating systems and software are also designed to be stable and able to recover from errors or power failures to minimize downtime.

Types of Industrial Control Computer

• Rack - mounted IPC: These are designed to be installed in standard 19 - inch equipment racks. They are suitable for applications where multiple computers or other devices need to be organized in a compact space, such as in data centers or large - scale industrial control rooms.
• Panel - mounted IPC: Panel - mounted industrial control computers are designed to be installed directly into the control panels of industrial equipment. They have a front - facing display and controls, making them easy to access and operate by technicians and operators on the factory floor.[!--empirenews.page--]
• Embedded IPC: Embedded industrial control computers are integrated into other industrial devices or systems. They are often used to provide control and computing capabilities to equipment such as industrial robots, CNC machines, or smart sensors. These IPCs are usually designed to be compact and have a specific set of functions tailored to the host device.

Precautions for using Industrial Control Computer

• Electrical Safety: Ensure that the industrial control computer is properly grounded to prevent electrical shocks. The power supply should be stable and within the specified voltage range. Any electrical connections to other devices should be made following proper wiring standards and safety protocols.
• Environmental Conditions: Although industrial control computers are designed to withstand harsh conditions, it's still important to monitor the environment. Avoid exposing them to extreme conditions beyond their specified limits, such as excessive heat, cold, or humidity. Regularly clean the computer to prevent dust and debris from accumulating and affecting its performance.
• Software and System Updates: Keep the software and operating system of the industrial control computer up - to - date. Regular updates can fix security vulnerabilities, improve performance, and add new features. However, before applying any updates, it's crucial to test them in a non - critical environment to ensure they don't cause any disruptions to the industrial process.

Things to consider when purchasing Industrial Control Computer

• Performance Requirements: Consider the computational requirements of your industrial control application. This includes factors such as the speed of the CPU, the amount of memory needed, and the processing power required for running control software and handling data. Make sure the IPC can handle the expected workload and any future expansion.
• Input/Output Capabilities: Evaluate the types and number of I/O interfaces you need. This depends on the sensors, actuators, and other devices you plan to connect to the computer. Look for an IPC with a sufficient number of serial ports, USB ports, Ethernet ports, and other specialized I/O interfaces such as analog and digital I/O channels.
• Operating System Compatibility: Choose an industrial control computer that supports the operating system you plan to use. Common operating systems for IPCs include Windows Embedded, Linux - based industrial distributions, and real - time operating systems. The operating system should be suitable for your application's requirements in terms of security, stability, and software support.
• Cost and Long - term Viability: Consider the initial cost of the industrial control computer as well as its long - term costs. This includes factors such as energy consumption, maintenance, and potential upgrade costs. A more expensive IPC with better quality and performance may be a more cost - effective option in the long run if it reduces downtime and improves productivity.

Terms of Industrial Control Computer

• Input/Output (I/O) Interfaces: The ports and connectors on the industrial control computer that allow it to communicate with external devices. These interfaces can be digital, analog, serial, USB, Ethernet, or other specialized types.
• Control Logic: The set of rules and algorithms programmed into the computer that determine how it controls the industrial process. Control logic can be implemented using programming languages such as ladder logic, C++, or Python, depending on the application and the capabilities of the IPC.
• Real - time Operating System (RTOS): An operating system designed to handle tasks with strict time constraints. In industrial control, RTOSs are used to ensure that critical control functions are executed in a timely manner, without being affected by other non - critical tasks.
• Data Acquisition: The process of collecting data from sensors and other sources in the industrial environment. Industrial control computers play a key role in data acquisition by providing the necessary interfaces and software to handle and store the collected data.