Rugged computers are worth the additional cost.

Personal computers (PCs) are becoming ubiquitous, not only in office environments, but also on the manufacturing floor, on warehouse forklifts, in public safety vehicles, and in practically every other workplace.

As computers have evolved into smaller, more powerful devices with easy-to-use graphical user interfaces and wireless networking, companies have been able to cost-effectively put technology within the reach of more employees, connecting them to management information and data collection systems. These distributed computing systems are streamlining operations and increasing productivity.

The important element enabling the growth of rugged industrial computing is the standardization of computer hardware. Application software can run on hardware from different manufacturers and even on different operating systems. Companies, therefore, have many options when purchasing computers for warehousing and vehicular uses.

In fact, some business and logistical applications will run on relatively inexpensive laptop PCs designed for home and office use. However, these computers may not stand up well in industrial and public safety environments. Another class of computers, called "rugged computers" is designed specifically to meet the requirements of these harsh environments. A number of factors should be considered when a company chooses whether a rugged computer is required for a particular environment and application. As with any piece of equipment that is available in different grades, the industrial-quality version will typically have a higher initial purchase price than the consumer version, but this additional cost may be justified due to better reliability, increased productivity, easier maintenance and other benefits.

Challenging Environment

When analyzing the type of computer required for industrial and onboard applications, many of the most important considerations pertain to the physical environment.

Shock and Vibration. One of most prevalent environmental problems for PCs is shock and vibration. PCs mounted on forklifts and construction equipment are subjected to especially high levels of shock and vibration, such as when a forklift travels back and forth over a dock plate at a distribution center. Shock and vibration can also be a problem for hand-held devices and computers mounted on carts. Hard-drives are particularly vulnerable to shock and vibration. So too are fans and any other moving parts.

Ambient Temperature. Extreme temperatures and rapid temperature changes can also wreak havoc on industrial and vehicular PCs, as outdoor environments can range from Phoenix summers to Buffalo winters. Forklifts in warehouse and distribution centers are continually loading and unloading, often times moving from one extreme temperature to another. For example, forklifts are typically moving in and out of a building, or in and out of a freezer.

Dust and Moisture. Many environments, particularly industrial and construction, can contain high levels of dust and other particulate matter. Traditional cooling fans will draw these contaminants into a PC, potentially causing overheating and other problems. In the food industry, the air is typically free of airborne contaminants; however, cleaning protocol subjects PCs to potentially damaging levels of moisture.

Rugged computers are designed to mitigate these environmental challenges. For example, many rugged computers manufactured by Glacier Computer eliminate moving parts by employing solid heat sinks instead of cooling fans and solid state flash memory instead of rotating hard drives. Glacier's Everest and Magnum series of computers are HALT tested (Highly Accelerated Life Testing) simulating three to five years of exposure to harsh environmental conditions.

Rugged computers also have special features and options to address the needs of particular applications and environments. Many data collection applications require the use of a scanning device, connected to the PC via a PS-2 or USB cable. Vibration or pulling by the operator can cause the cable to become dislodged. This can cause a series of problems, including the need to reboot the PC to recognize the device. More serious issues include scanners being run over by the forklift on which it is mounted and, thus, being destroyed. These problems can be prevented with rugged computers that offer locking clamps that securely grip cables.

An additional option that is critically important in some environments is a heated touch screen to prevent condensation forming in applications where the computer travels from a freezer to a warmer environment and then back again.

Electrical Power Source

Another environmental factor is the electrical power source. Forklifts and construction vehicles do not provide a stable and dependable power supply. A rugged computer should be designed to handle voltage spikes that often occur on older 24, 36, or 48 volt forklifts, as well as voltage sags on 12 volt vehicles. Glacier Computers are designed to accommodate these electrical environments without the need for any external transformers or filters. Rugged computers designed for the industrial environment should also offer an internal uninterruptible power supply. An internal UPS will keep a computer up and running and connected to the network during vehicle battery changes.

The Human Element

Human operators also place significant demands on industrial and onboard vehicular PCs.

Ergonomics. If a computer is not highly usable, employees will resist using it, or they will perform tasks inefficiently and inaccurately. Special ergonomic features are available with rugged computers that are typically not offered with consumer and office computers. For example, rugged computers come with mounting options that allow for convenient and secure placement, where controls are easily reached and the screen is easily viewed. Proper placement on a forklift or other vehicle can be critical for safe operation. For additional safety, Glacier computers can be configured to turn off the LCD display whenever the forklift is in motion.

Glacier provides a touch screen which can boost productivity and reduce errors, especially when used in conjunction with a graphical user interface that presents choices to the operator. Rugged computers can be equipped with special displays that enhance visibility during outdoor use.

Operator Error and Abuse. Employees vary with their level of comfort with computers, as well as the care and patience they exhibit. Some people are unfamiliar with the delays that can exist on wireless networks, and they can become frustrated when they perceive the computer as limiting their efficiency. In such situations, the operators can be less than gentle with the equipment, and therefore, the computer must be built to withstand such treatment.

A one-button, "soft shutdown" feature is useful, because in an industrial or public safety environment, users rarely have the patience to wait for the computer to properly power off. With the simple push of this button, the unit goes through an orderly, graceful shutdown extending hard drive life.

Ease of Maintenance

In selecting a computer for an industrial or vehicular application, it is important to not only consider the needs of the users, but to also consider the needs of the staff responsible for supporting and maintaining the computer.

Remote Hardware Diagnostics. Some industrial grade computers offer extensive remote hardware diagnostics via the wireless network. The Information Technology staff can keep an eye on all the computers on a network, even when they are distributed over a large geographic area. For example, the Glacier Onboard Command Utility enables an administrator to access and monitor attributes such as internal temperature and frequency of rebooting. In addition, the onboard command utility allows for configuring unit features such as programmable function buttons.

Windows XP Embedded OS. At Glacier, we give our customers the option of using the Windows XP Embedded operating system on our rugged computers, an option not available with consumer and office PCs. A custom USB thumb drive recovery system allows for embedded XP units to be restored in only eight minutes without being removed from their installed location.

This operating system is a licensed Microsoft product which resides on a small flash drive and offers greater protection against users making unauthorized changes. Often a single device will be used by multiple operators, such as when there are multiple shifts. XP Embedded prevents users from making changes that might cause confusion or error by other users.

Industrial Grade, Worth the Price?

When purchasing computers for industrial and vehicular applications, you generally get what you pay for. PCs designed for consumer and office use are relatively inexpensive to purchase, but they do not provide the features and robust construction of rugged industrial computers.

John Geary is Vice President, Glacier Computer.

www.glaciercomputer.com