Overview
As automation equipment continues to evolve toward software-defined control, manufacturers are increasingly replacing traditional PLC architectures with industrial PCs. A robotics-focused equipment builder developing automated rolling machines required a compact, fanless system capable of handling real-time control, vision processing, and dense I/O inside an electrical cabinet. Premio’s semi rugged small form factor industrial computer delivered the performance, reliability, and industrial-grade design needed to support this transition.
Learn more about the differences between PLCs and Industrial PCs >>
Challenges
- Limited CPU flexibility when replacing PLC controllers with PC-based control systems
- Exposure to continuous shock and vibration requiring a fanless, solid-state platform
- Tight space constraints inside an electrical cabinet requiring compact industrial hardware
- Requirement for high-density I/O including multiple LAN ports, USB connections, and HDMI output
- Need for an industrial system certified for safety and long-term deployment
Solution
- Premio’s BCO-3000-RPL Series, a semi-rugged small form factor fanless industrial computer
- Support 12th/13th Gen Intel Core TE processors (configured with Intel Core i5-13500TE)
- Rich onboard I/O including 3x 2.5GbE LAN, multiple USB ports, and HDMI
- Fanless aluminum chassis tested to MIL-STD-810G for shock and vibration
- Optional DIN rail mounting kit enabling flexible cabinet installation
Benefits
- Flexible PLC replacement with software-driven control
- Reliable 24/7 operation in mechanically active systems
- Simplified cabinet integration with optional mounting flexibility
Company Overview
The company designs and manufactures automated machinery focused on precision rolling applications. Its solutions integrate robotics, sensing, and proprietary software to improve consistency and throughput in production environments. Ongoing innovation in software-centric automation enables scalable and adaptable machine designs.
The Challenges
Moving Beyond Traditional PLC Controllers
Legacy PLC systems limited the ability to implement advanced control logic and vision-based inspection. The company required an industrial PC capable of running its proprietary control software while maintaining real-time responsiveness. CPU performance and long-term availability were critical considerations.
Shock and Vibration from Mechanical Motion
Although deployed indoors, the rolling system introduced constant mechanical movement. Traditional PCs with fans were prone to failure under vibration. A rugged, fanless platform was required to ensure system longevity.
Space Constraints Inside Electrical Cabinets
All electronics were housed within a compact electrical cabinet alongside power and control components. The computing system needed a small footprint to fit cleanly without redesigning the enclosure. Mounting flexibility was also important to support different cabinet layouts.
High I/O Requirements for Vision and Controls
The system relied on multiple USB cameras for inspection and monitoring. Additional LAN ports were required to communicate with sensors and actuators across the machine. HDMI output supported a local display for diagnostics and setup.
Compliance and Long-Term Reliability
Industrial certification was essential for deployment in production environments. The system needed UL safety compliance and stable operation across a wide power input range to meet industrial standards.
The Solution
Semi Rugged Small Form Factor Industrial Computer
Premio’s BCO-3000-RPL Series, Semi-Rugged SFF Fanless Industrial Computer was selected as the core control platform. Installed inside the electrical cabinet, the system replaced PLC hardware with a more flexible, PC-based architecture. An optional DIN rail mounting kit allowed the system to be securely mounted while preserving cabinet space.
Intel Core Processing for Software Control
Supporting 12th and 13th Gen Intel Core TE processors, the BCO-3000-RPL Series provided a flexible computing platform for software-defined control. For this application, the system was configured with an Intel Core i5-13500TE processor to deliver the compute performance required for real-time machine control and image processing. The hybrid-core architecture balanced performance and power efficiency, ensuring consistent execution of the company’s control software.
Fanless, Shock-Resistant Design
The fanless aluminum chassis eliminated moving parts that could fail under vibration. The system was validated to withstand up to 50G shock and 5 Grms vibration with solid-state storage. This provided reliable operation in a mechanically active environment.
Dense Industrial I/O Integration
With three 2.5GbE LAN ports, multiple USB 3.2 connections, and HDMI output, the system supported all peripherals without additional expansion. USB cameras connected directly for vision tasks, while LAN ports interfaced with sensors and actuators. This streamlined system wiring.
Certified and Deployment-Ready Platform
UL62368 certification ensured compliance with industrial safety standards. A wide 9–36VDC power input range supported stable cabinet-level power delivery. Ubuntu Linux compatibility aligned seamlessly with the company’s software stack.
The Benefits
Greater Control Architecture Flexibility
Replacing PLCs with an industrial PC enabled advanced software logic and easier updates
Increased System Reliability
Fanless, shock-resistant design delivered stable operation in continuous-use environments
Flexible Cabinet Integration
Optional DIN rail mounting allowed the system to adapt to different electrical cabinet layouts, supported by Premio’s Los Angeles-based engineering team
Conclusion
By adopting a semi rugged industrial edge computer, the manufacturer successfully transitioned from PLC-based control to a software-driven architecture. Premio’s BCO-3000-RPL Series delivered the performance, durability, and connectivity required for automated rolling systems operating inside compact electrical cabinets. The result is a reliable and scalable control platform built for modern automation.
For organizations with similar requirements or those seeking guidance on rugged edge computing solutions, Premio’s rugged edge technology experts are available to help. Reach out to sales@premioinc.com to start the conversation or fill out the form here.