How To Build Ruggedized PCs

Most PCs lead comfortable, indoor lives, humming along until someone messes with the software, a component fails or it's time to retire them.

Not so for PCs in manufacturing, construction and other harsh environments. These systems really take a beating. They can be jarred by industrial equipment, or exposed to rain, snow and extreme cold and heat. They may be splashed by caustic chemicals, or pounded on by less-than-gentle workers.

Systems builders who can create ruggedized systems have access to new, lucrative markets. By learning to build battle-hardened boxes, you can expand your business, attract new clients and widen your repertoire of systems-building skills. This systems recipe will show you how.

You will first need to assess the hazards of the industry for which you want to build. The best way to do this is with a site survey to spot what I call "natural enemies" (see chart, below). But if it's either impossible or impractical to personally visit the site, at least talk at length with the client. Try to fully understand its operation and environment. Don't hesitate to ask questions or request photographs or videos.

Now it's time to spec out the system and start building. Remember, there is no such thing as a computer that's impervious to all hazards. Let's take a look at practical solutions to some common hazards.

* The case. A PC's enclosure provides both a rigid chassis for construction and a coat of protective armor. The choice of case is arguably the single most important decision for protecting your CPU and internals from harm. First, choose the right form factor. Standard desktop and tower cases are stamped out of sheet metal of various gauges; heavier gauges, of course, provide better rigidity and protection. Aluminum exteriors cost a bit more, but they provide excellent protection, thermal advantages and good looks.

Rack-mount cases offer industrial-grade protection and security, along with the organization of a standard 19-inch rack.

* Play it cool--and clean. Your choice of case and power supply will require a plan for cooling. Include additional fans whenever possible. In industrial situations, air filters can provide front-line protection from dust and airborne particles. Also, don't overlook the need to regularly clean filters in dirty environments. Finally, provide adequate space for cooling. You also may want to consider liquid cooling. Recent advances in this technology have made it more practical in situations where superior cooling is needed.

* Power to the PC. At a minimum, always use an external, high-quality surge suppressor with Radio Frequency Interference filtering, and always ensure proper grounding. A high-quality power supply can pay off here, too, since low-grade power supplies are less tolerant of "dirty" power sources. PCs that travel need to be prepared for anything. More sophisticated line filters and filters with "line conditioning" to regulate power in a safe range are available in 19-inch rack-mounts. *

Andy McDonough is an educator, engineer and freelancer based in New Jersey.