Enhancing Asphalt Control Systems with x86 Super-Rugged Edge Computers
Effective production management relies heavily on control systems and centers to oversee operations, ensuring everything runs efficiently and safely. However, this wouldn’t be possible without the power of edge computing. Edge computers work in the background, sending real-time data from factory machines to control centers for immediate analysis and decision-making. In this case study, an asphalt production control systems provider selected Premio’s rugged edge computing solution to enhance their control systems, streamlining operations and boosting system integration for improved performance.
Challenge:
- Relied on a commercial-grade desktop workstation.
- Fanned system posed long-term risks of system failures.
- Needed a compact design to fit into the control center cabinet.
- Required long-term reliability and consistent performance.
- Faced challenges in securing stable mounting for portable deployments.
Solution:
- C&T’s RCO-3000 Series Small Form Factor Computer (RCO-3000-CFL).
- Super-rugged, fanless design built for industrial environments,
- Provided secure and flexible mounting options.
- Integrated Intel Core TE processor to enhance control software and ensure longevity.
- Offered rich IoT connectivity for seamless integration with metering devices.
- Included scalable EDGEBoost I/O technology for future expansion.
- Featured a hot-swappable SSD Bay for easy data offloading.
Benefits:
- Established a reliable edge computing hardware solution.
- Developed a custom BIOS for specific configuration needs.
- Pre-loaded the manufacturer's proprietary software and operating system.
- Achieved over 2 years of successful, consisten deployment.
Company Background
For over 30 years, this manufacturer has built a wide range of control systems for the asphalt and construction aggregate industries. They provide everything from designing control centers to developing automation software, offering a complete system solution that covers every aspect of asphalt production.
The Challenge
Before partnering with C&T, the control systems manufacturer used standard commercial desktop workstations. Although these desktops were convenient for office use, the fell short in the harsh conditions of asphalt production and lacked the long-term support needed for embedded systems. Key features were missing, and the desktops revealed significant challenges in ensuring long-term reliability. Recognizing the need for industrial-grade solutions, the manufacturer began searching for an edge computing hardware partner that could offer a more durable and reliable system for their asphalt control operations.
The Drawbacks of Using Commercial Hardware in Industrial Settings
One of the biggest issues with using commercial hardware in industrial environments is the risk of dust and debris clogging active cooling systems. The controls equipment manufacturer experienced this firsthand when their previous solution began to fail due to dust buildup, which damaged the cooling fans and led to critical production downtime. In industrial settings, especially with mission-critical machinery, sudden system failures can not only disrupt production but also create serious safety hazards.
Another challenge was the lack of long-term product support. Commercial hardware often has a limited support lifecycle, with products being discontinued and replaced with newer models. These frequent changes made it difficult for the manufacturer to maintain a reliable, consistent solution that could be easily integrated into their asphalt control systems.
Additionally, the size and lack of secure mounting options became a problem when moving control systems between different sites. The existing solution was bulky and didn’t offer any standardized mounting points. A smaller form factor with secure mounting options was essential for an easy fit into the overall equipment control system.
The Solution: RCO-3000 Series Small Form Factor Computer
After identifying the issues faced by the asphalt control system manufacturer, C&T recommended the RCO-3000 Series, a rugged industrial small form factor computer. This x86 computer is designed to deliver real-time performance, flexible EDGEBoost I/O options, and scalability for future needs, all while being extremely durable and compact.
Built for Industrial & Mobile Durability
The RCO-3000 Series is built to handle the tough conditions of both industrial asphalt plants and portable work environments. Its fanless and cableless design improves durability by reducing failure points common in commercial desktop workstations, and it prevents dust and debris from entering the system. Key features include:
- Wide Operating Temperature (-25°C to 75°C)
- Shock & Vibration Resistance (MIL-STD-810G)
- Wide Power Input (9-48VDC)
- Power Protection (OVP, OCP, RPP)
- UL Listed Certification of safety
C&T's RCO-3000 series now supports 14th Gen Intel® Core™ processors. Explore RCO-3000-RPL.
Optimized for Asphalt Control Systems
The RCO-3000 Series is specifically designed to handle various IoT sensors and provide real-time data analytics, making it ideal for asphalt control rooms. Powered by an Intel Core TE processor, it ensures smooth operation for critical tasks like drum mixing and asphalt blending. By connecting to multiple metering devices and vision cameras, the RCO-3000 allows operators to monitor and manage asphalt plant processes in real-time with minimal delays.
Futureproofing for Long-Term Use
The RCO-3000’s use of the Intel Core TE processor guarantees a 10-year product support lifecycle, ensuring long-term reliability without the need to worry about hardware updates or software compatibility issues.
Additionally, the RCO-3000 comes with EDGEBoost I/O expansion options, allowing the control systems manufacturer to scale up as needed. Whether it’s adding NVMe storage, PoE support, 10GbE LAN, or even edge AI capabilities, the EBIO technology provides the flexibility to meet future requirements without replacing the whole system.
One feature that proved particularly useful was the hot-swappable SSD bay, which allowed the manufacturer to easily swap out storage drives without opening the computer or relying on cloud uploads, streamlining their data offloading process.
The Benefits
After recognizing the weaknesses and long-term risks of their previous solution, the control systems manufacturer aimed to find a reliable hardware partner that could offer dependable solutions, strong support, and clear communication. C&T, a global leader in rugged edge computing hardware, proved to be the right choice. With over 35 years of expertise in engineering, supply chain management, and sales, C&T’s team provided expert guidance, ensuring a smooth and successful deployment.
Additionally, C&T’s ability to create a custom BIOS tailored to the manufacturer’s needs, along with pre-loading their proprietary software, greatly simplified the control center manufacturing process. By integrating the fully configured RCO-3000 Series x86 rugged small form factor computer without needing further adjustments, the manufacturer was able to overcome previous hardware challenges for a seamless solution. Since 2022, C&T has supplied the RCO-3000 Series without major issues, reinforcing the strength and reliability of their partnership.
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