Overview
As grain and bulk material facilities adopt autonomous equipment to improve safety and loading efficiency, dependable motor control becomes essential to keeping complex mechanical systems moving. An industrial automation developer required a compact primary control computer that could operate inside an outdoor enclosure while running software-based PLC logic and communicating with multiple field devices. Premio’s super-rugged fanless minicomputer provided the processing capability, industrial connectivity, and environmental resilience needed to support the autonomous railcar handling system.
Challenges
- Reliable processor performance for continuous software-based PLC execution and primary motor control
- Insufficient onboard connectivity for at least two USB devices and two serial control interfaces
- Exposure to outdoor temperature changes, dust, vibration, and electrical fluctuations inside a field enclosure
- Limited enclosure space requiring a compact computer with flexible industrial mounting
- Need for a UL Listed computing platform suitable for integration into industrial equipment
Solution
- Premio’s super-rugged fanless minicomputer (RCO-1000-ASL-10)
- Intel Atom x7000RE series processor for efficient software-based PLC control
- Four onboard USB ports and two configurable serial ports for industrial device integration
- Wide temperature fanless design with 9 to 36 VDC power input
- Compact chassis with wall, side, VESA, and optional DIN rail mounting support
Company Overview
An industrial automation developer creates autonomous equipment for railcar loading operations at grain and bulk material facilities. The company excels at combining machine learning, computer vision, precision robotics, and industrial controls to remove workers from hazardous railcar tasks. Its future direction centers on expanding intelligent automation that improves facility safety, loading consistency, and operational throughput.
The Challenges
Continuous PLC Processing
The railcar automation system depended on a primary computer to execute software-based PLC logic and coordinate motor driven equipment. Any interruption in control processing could delay mechanical sequences or prevent the automated system from completing its operating cycle. The company therefore needed an efficient industrial processor capable of supporting continuous control workloads without relying on a traditional hardware PLC.
Multiple Control Interfaces
The primary controller needed to communicate with several components installed throughout the automated railcar system. At least two USB connections were required for peripheral equipment, while two serial interfaces were needed for industrial controllers, motor systems, or other field devices. A computer without sufficient onboard connectivity would require additional adapters, increasing wiring complexity and potential points of failure.
Outdoor Enclosure Conditions
The computer would be installed inside an enclosure positioned outdoors near active rail loading equipment. Although protected by the enclosure, the system could still experience significant temperature changes, airborne dust, equipment vibration, and fluctuations in available power. A conventional office computer was not designed to provide dependable control under these industrial conditions.
Constrained Installation Space
Control enclosures contain power supplies, terminal blocks, motor control hardware, communication equipment, and extensive field wiring. The available space for the main control computer was therefore limited, making system size and cable accessibility important design considerations. The selected computer needed a compact footprint and practical mounting options that would simplify integration into the existing enclosure layout.
Industrial Compliance Requirements
Equipment incorporated into an industrial automation system must support the safety and compliance objectives of the complete machine. Selecting components without recognized industrial certification could complicate system documentation and customer acceptance. A UL Listed computing platform is preferred to support a more straightforward integration and approval process.
The Solution
Rugged Primary Control Computer
Premio's RCO-1000-ASL Series of rugged fanless industrial computers provides a scalable platform for industrial automation and edge control applications. The series includes four models: RCO-1000-ASL-10, RCO-1000-ASL-20, RCO-1000-ASL-20-OOB, and RCO-1000-ASL-30, offering one to three EDGEBoost I/O expansion slots to support application-specific connectivity requirements. Additionally, the RCO-1000-ASL-20-OOB features built-in out-of-band remote management for enhanced system monitoring and maintenance.
For this autonomous railcar system, the RCO-1000-ASL-10 was selected as the primary motor control computer. Installed inside the outdoor control enclosure, the compact fanless computer serves as the central platform for executing the company's software-based PLC application. Equipped with one EDGEBoost I/O expansion slot, the system can be configured with additional HDMI, DisplayPort, DIO, COM, and USB interfaces to support the application's connectivity needs. Its rugged embedded design delivers the reliability required for continuous operation in demanding environments near grain loading facilities and rail infrastructure.
Efficient Industrial Processing
The system supports Intel® Atom® x7433RE (4-core, 9W TDP) and x7835RE (8-core, 12W TDP) processors, delivering an efficient balance of performance and power consumption for industrial edge workloads. This processing architecture enables the computer to run control logic, manage motor commands, and coordinate connected devices while maintaining energy-efficient operation. The processors also offer 10-year product lifecycle support, helping ensure long-term availability and platform stability for industrial deployments. Combined with the fanless design, the system minimizes maintenance requirements by eliminating a mechanical cooling component that could otherwise draw dust into the system.
Integrated USB and Serial Connectivity
The RCO-1000-ASL-10 provides three USB 3.2 Gen 2 ports, one USB 2.0 port, and two onboard serial ports supporting RS 232, RS 422, and RS 485 communication. These interfaces satisfy the requirement for a minimum of two USB connections and two serial connections without requiring an expansion module. The integrated ports enable direct communication with control peripherals, service devices, and industrial equipment installed throughout the railcar automation system.
Resilience for Outdoor Deployment
A wide operating temperature range from -40°C to 70°C helps the computer remain operational through seasonal conditions encountered by outdoor rail loading equipment. Its 9 to 36 VDC input provides flexibility when connecting to industrial power infrastructure, while overcurrent and overvoltage protection help guard against electrical irregularities. The fanless metal chassis and resistance to shock and vibration with MIL-STD-810H certification further strengthen its suitability for operation near moving machinery.
Flexible Enclosure Integration
Measuring 150 x 105 x 56 millimeters, the computer can fit into control enclosures where internal space is limited. Wall, side, and VESA mounting options allow the integrator to position the system around existing wiring and control hardware, while an optional DIN rail kit supports conventional control cabinet installation. Its UL Listed status adds another layer of confidence when the computer is incorporated into the complete industrial automation platform.
The Benefits
Responsive Engineering Support
Backed by Premio's Los Angeles headquarters, our engineering team provides responsive support to help accelerate system configuration, integration, and deployment.
NDAA/TAA Compliance Assurance
The RCO-1000-ASL-10 supports organizations requiring trusted computing solutions that align with government and regulated industry procurement standards. NDAA and TAA compliance helps simplify deployment considerations for customers with strict sourcing requirements, providing greater confidence when integrating industrial computing platforms into critical automation infrastructure.
Conclusion
By integrating the RCO-1000-ASL-10 into its outdoor control enclosure, the industrial automation developer gained a compact and rugged platform for software-based PLC execution and primary motor control. The computer’s onboard connectivity, wide temperature capability, and flexible mounting directly address the requirements of autonomous railcar equipment. The result is a more streamlined control architecture designed to support safer and more reliable bulk material loading operations.