The construction industry is undergoing digital transformation driven by the adoption of AI and the proliferation of IoT. Newer excavation and construction vehicles are increasingly embedded with smart technologies that enable real-time decision-making, predictive maintenance, and complete data transparency. This case study explores how one of the world’s largest construction vehicle and equipment manufacturers partnered with Premio to assist in navigating their data logger hardware complexities for its next-generation vehicles.
Company Background
With a global footprint and decades of innovation in heavy machinery, the company is recognized as a leader in the design and manufacturing of construction vehicles and equipment. As the market shifts toward intelligent and autonomous machines, the organization has invested heavily in R&D to explore next-generation vehicle platforms.
The company formed a specialized research and development team focused on integrating digital technologies into their excavation vehicles. Their mission was to deliver smarter, safer, and more connected equipment by embedding AI, sensor fusion, and remote monitoring into their next generation fleet.
The Challenges
As the R&D team worked on prototyping the next generation of smart excavation vehicles, they encountered several key technical challenges when attempting to integrate a data logger into the vehicles. Data loggers provide the team with specific vehicle telematics and insights that are necessary for improving equipment performance, safety, and maintenance planning. However, there were hurdles that needed to be addressed to optimize their data logger.
1. Exposure to Rugged, In-Vehicle Operations
The data logger system had to function reliably inside large excavation vehicles operating in extreme conditions. The team struggled to find a system that offered sufficient processing power in a compact form factor while still meeting the stringent industrial requirements for vibration resistance, wide temperature tolerances, and a fanless enclosure to prevent dust ingress.
2. Immediate Telematic Data Retrieval Difficulties
To enable smarter excavation workflows, the R&D team designed systems that depended on real-time data streams from various onboard sensors. Delays in telemetry could disrupt decision-making processes and compromise vehicle performance in critical tasks like load balancing, obstacle detection, and predictive maintenance.
Their early iterations used cloud-based data processing that introduced latency and connection issues, especially in off-grid environments. This emphasized the need for a local data logger with low-latency performance, powerful edge processing capabilities, and the ability to handle telemetry workloads on-site, in real time.
3. Limited Field Data Accessibility
In addition to real-time processing, the team needed an accessible method to retrieve and offload data easily in the field. Since the data logger is required to store large volumes of mission-critical telematic information, engineers needed to gain access to the storage drive for seamless data offloading procedures. Although wireless data transfer is possible, it required the vehicle to dock and introduce lengthy downtimes to upload the data to the cloud.
Serviceability and data accessibility in the field emerged as another critical hurdle. In many deployment scenarios, excavation vehicles operated in remote or off-site locations where cloud synchronization is unavailable. The R&D team required a way to physically retrieve data quickly and securely, with minimal downtime or disruption to vehicle operations.
4. High Density Connectivity Demands
The prototype vehicles were equipped with an extensive network of onboard sensors and peripherals, including high-resolution cameras, LiDAR scanners, GPS modules, and environmental monitors. Each of these components generated high-bandwidth data streams that needed to be logged in real time without interruption.
To manage this data load effectively, the R&D team required the data logger to accommodate high IoT port density. Standard embedded systems often fell short, forcing teams to rely on external switches or adapters that added complexity, increased wiring, and introduced potential points of failure.
5. Remote Communication Challenges
The ability to remotely access the vehicle systems was crucial for telemetry monitoring, remote diagnostics, and over-the-air updates. Given that the machines often operated in areas without wired infrastructure, the R&D team needed a data logger capable of wireless connectivity through multiple channels, including Wi-Fi, cellular networks, and GPS.
The Solution
Premio evaluated the technical challenges of deploying a reliable data logger in smart excavation vehicles and recommended the RCO-3000 Series. This compact, high-performance edge computer is designed specifically for industrial environments with its balance of real-time performance, industrial durability, and support for EDGEBoost I/O (EBIO) technology. Explore how the RCO-3000 Series proved to be the ideal platform to support the development team’s telematics and edge intelligence initiatives.
Real-Time, High-Performance Processing
To meet the demands of in-vehicle telematics and real-time decision-making, the RCO-3000 Series is equipped with a 10th Gen Intel® Core™ TE processor and high-speed DDR4 memory. This configuration enables the system to process high volumes of sensor data locally, without relying on cloud infrastructure. With onboard edge processing, the smart excavation vehicle could support critical functions like predictive maintenance and real-time alerts. For the R&D team, this meant immediate access to telematic insights and the ability to validate intelligent features under real-world conditions.
Hot-Swappable SSD for Seamless Field Data Offloading
The RCO-3000 Series features a front-accessible, hot-swappable 2.5” SATA SSD bay, enabling field technicians to remove and replace storage drives without shutting down the system or opening the enclosure. This significantly simplified data retrieval in remote environments, allowing the team to offload large volumes of collected data quickly and efficiently. What once required downtime and specialized support could now be completed within minutes, accelerating field testing cycles and improving overall system serviceability.
EDGEBoost I/O Technology for Scalable IoT Connectivity
To address the vehicle’s high-density sensor integration requirements, the RCO-3000 Series leveraged modular EDGEBoost I/O technology. This enabled support for four additional GbE RJ45 ports while maintaining the same compact enclosure. It gave the R&D team the flexibility to maintain their original system architecture while ensuring reliable, high-throughput connectivity for real-time data logging and analysis.
Built Super-Rugged. Built Ready for In-Vehicle Integration
The RCO-3000 Series features a fanless and cableless architecture that eliminates common points of failure caused by shock, vibration, and dust ingress. Its fully enclosed, industrial-grade housing makes it well suited for the extreme conditions encountered in excavation and construction sites.
In addition to its rugged build, the RCO-3000 maintains a compact footprint and offers multiple standard mounting options. This provides seamless installation within the vehicle’s existing control enclosures and allowed the R&D team to accelerate deployment across multiple prototype units without requiring redesigns or interrupting ongoing system integration efforts.
Built-In Wireless Communication Support
To meet the requirement for robust remote connectivity, the RCO-3000 Series supported integrated wireless modules for Wi-Fi, 4G LTE, 5G, and GPS. This eliminated the need for external dongles or adapters and provided stable, high-bandwidth links for data transmission, location tracking, and remote management. With this built-in capability, the R&D team ensured their vehicles could stay connected even in remote and infrastructure-scarce environments.
The Benefits
For the construction equipment manufacturer, partnering with Premio meant more than just sourcing reliable hardware. It established a lasting relationship grounded in engineering collaboration, technical depth, and a shared commitment to industrial innovation.
Product Longevity Aligned with Industrial Lifecycles
Premio’s focus on embedded product longevity ensured that the RCO-3000 platform would remain available for years to come. This stability eliminated the risk of mid-development obsolescence, allowing the R&D team to confidently move from prototype to production without disruptive redesigns.
Dedicated Engineering for Custom Integration
Premio’s Field Application Engineering (FAE) team provided hands-on collaboration, working closely with the manufacturer’s developers to fine-tune BIOS settings, firmware configurations, and device drivers. This technical partnership accelerated development cycles and ensured the final solution met all operational and regulatory requirements.
Compliance with Regional Industry Standards
Premio, an NDAA and TAA compliant manufacturer, provides assurance that the solution adhered to government and industry procurement standards. Additionally, Premio’s wide portfolio of rugged edge computers is expected to meet UL safety standards certification for accelerated time-to-market and deployment peace of mind. This was especially important as the R&D team prepared for global deployments in both public and private infrastructure projects.
A Trusted Hardware Partner for Future Growth
Beyond immediate implementation, Premio’s ongoing product roadmap and deep experience in edge computing gave the R&D team confidence in their long-term technology stack. With a reliable partner supporting the foundation of their smart vehicle platform, they could focus on innovation and scaling the solution across their global fleet.