A leading provider of safety-rated I/O interlock and process control solutions needed a compact yet powerful controller for its in-house manufacturing machines. The platform had to operate reliably in demanding semiconductor environments while meeting long-term availability and regulatory requirements. This case study highlights how Premio’s DCO-1000-ASL Series DIN-rail fanless embedded computer delivers the performance, durability, and lifecycle support needed to keep mission-critical manufacturing operations running smoothly.
Challenges
- Limited space required a small form factor controller with sufficient CPU and memory performance
- Need for high bandwidth memory to support responsive real time Linux control applications
- Requirement for both wired and wireless connectivity to support flexible factory networking
- Harsh manufacturing conditions demanded high shock and vibration tolerance
- UL, TAA, and NDAA compliance was mandatory for deployment in regulated environments
Solution
- Premio’s DIN-Rail Fanless Embedded Computer (DCO-1000-ASL)
- Intel embedded Atom x7433RE CPU for reliable real time Linux operation
- DDR5 memory support enabling higher bandwidth and improved system responsiveness
- Four LAN ports and WiFi enabling flexible industrial networking
- MIL-STD-810G shock and vibration compliant design for rugged environments
- UL Listed system with full TAA and NDAA compliance
Benefits
- Fast, Local Engineering Support
Company Overview
An engineering-focused manufacturer has built its reputation around real-time, safety-rated I/O control solutions for mission-critical industrial applications. Known for designing and delivering highly reliable control systems, the company serves some of the most demanding industrial environments. Backed by decades of experience, it continues to evolve its automation technologies to meet the growing complexity of modern manufacturing systems.
The Challenges
Compact Industrial Form Factor
The manufacturing equipment needed a controller compact enough to fit within space-constrained enclosures without compromising processing performance. Larger industrial systems proved impractical for machine-level integration. A streamlined, compact design became essential to simplify installation while still maintaining reliable performance.
Memory Performance for Real Time Control
Maintaining deterministic behavior in real-time Linux control applications depends heavily on fast, efficient memory access. As workloads grew more demanding, older memory technologies began to introduce latency and limit system responsiveness. Adopting higher-bandwidth memory became a necessary step to support modern control requirements.
Flexible Network Connectivity
As factory networks evolved, manufacturing environments began to rely on a mix of wired and wireless connectivity. Limiting communication to Ethernet alone made deployments less flexible and restricted how systems could be arranged on the factory floor. To support a wider range of networking scenarios, the platform needed multiple LAN ports alongside built-in Wi-Fi.
Rugged Manufacturing Environment
On the manufacturing floor, constant vibration and occasional shock placed added stress on standard computing hardware. Any resulting instability risked system downtime and costly production delays. The controller therefore needed to withstand these physical stresses reliably and consistently.
Regulatory Compliance
Safety and government-related requirements made UL listing, along with TAA and NDAA compliance, a baseline expectation. Without these certifications, systems could not be deployed in regulated semiconductor environments. Compliance therefore had to be built directly into the platform from the start.
The Solution
Premio’s DIN-Rail Fanless Embedded Computer (DCO-1000-ASL)
Premio’s DCO-1000-ASL compact, fanless embedded controller was selected to serve as the Linux-based control platform for the company’s in-house manufacturing machines. Built specifically for industrial automation, it delivers dependable performance while operating silently in harsh environments. Its embedded architecture is designed to support long-term manufacturing continuity and extended lifecycle requirements.
Embedded Intel Atom Processing
The Intel Atom® x7433RE processor delivers efficient, reliable performance optimized for industrial and real-time applications. Built on Intel’s embedded roadmap, it ensures up to ten years of long-term availability and validation stability. This long lifecycle allows the control system to scale without frequent redesigns.
High Bandwidth DDR5 Memory
Support for DDR5 memory provides higher bandwidth and improves overall system responsiveness. This allows data to be handled more quickly for real-time control tasks and safety-critical applications. The resulting memory performance helps deliver smoother, more deterministic system behavior.
Wired and Wireless Network Flexibility
Four integrated LAN ports, combined with Wi-Fi support, offer flexible connectivity across a wide range of industrial networks. This allows the controller to support multiple control domains while adapting to wireless factory layouts. The result is greater deployment flexibility and smoother, more straightforward system integration.
Ruggedized Mechanical Design
On the manufacturing floor, constant motion and mechanical stress are unavoidable. Built to meet MIL-STD-810G shock and vibration standards, Premio’s DCO-1000-ASL continues to operate reliably in these demanding conditions. This rugged durability helps maximize uptime while minimizing maintenance interruptions.
Built In Compliance Certifications
Designed with compliance in mind, the platform is UL Listed and meets both TAA and NDAA requirements. This built-in certification streamlines deployment across regulated industrial and semiconductor environments. By addressing compliance at the system level, it reduces risk and helps accelerate implementation timelines.
The Benefit
Fast, Local Engineering Support
Long-term stability is reinforced through direct access to Premio’s Los Angeles–based engineering team. Fast response times and hands-on support help resolve issues quickly throughout deployment and operation. This close support relationship builds confidence in sustained performance, even during the extended validation cycles common in semiconductor manufacturing.
Conclusion
By choosing Premio, the manufacturer built a dependable Linux-based control foundation for its in-house manufacturing machines. The DCO-1000-ASL delivered the performance, flexible connectivity, regulatory compliance, and long-term stability required in semiconductor environments. In doing so, it strengthened system reliability while establishing a scalable platform ready to support future growth and sustained operational performance.