Did you know that factory downtime can bleed US businesses dry to the tune of $260,000 every single hour? That is why I am so enthusiastic about custom panel PC design. I have seen firsthand how a computer, precisely engineered for a specific job, can completely change how things are done across a huge range of industries. This includes making manufacturing faster and more efficient, and even improving the ways medical devices work.
If you use off the shelf solutions, you often have to make compromises. You might have to give up important features, processing speed or even worry about the physical size of the unit. However, custom panel PC design eliminates these problems. You end up with a solution that is precisely tailored to what you specifically need. This is much more involved than simply sticking your logo on a generic product. It is a thorough design process where every detail of your requirements are carefully considered. We make it our mission to deliver real value through designs that are fully optimized.
The Advantages of Custom Panel PCs
There are significant advantages to having a PC designed specifically for your needs. Here are some of the key benefits that I have personally observed:
- Performance That Is Fully Optimized: A custom build lets you pick exactly which components your application needs. This prevents wasted resources and increases speed. I have seen carefully chosen processors and memory make a huge difference in improving processing power.
- A Longer Useful Life: When you use industrial grade components and design for your specific environment, you extend the lifespan of your panel PC and reduce downtime. One of my clients experienced failures every year with standard computers because of dust and heat. A custom, ruggedized build extended the computer’s lifespan to five years. This resulted in big cost savings.
- Easy Integration: A custom panel PC will fit in smoothly with what you already have. This simplifies installation and prevents compatibility problems. I specialize in creating solutions that integrate easily into existing environments.
- Unique Branding: A custom enclosure and interface reinforces your brand and creates a professional image. I can incorporate your company colors, logos and other branding elements into the design.
- Necessary Certifications: Certain industries, such as medicine and aerospace, have specific certification requirements. A custom design makes sure that your panel PC meets all the necessary regulations. My team stays up to date on all industry regulations.
Creating a custom panel PC design might seem difficult. But with the right partner, the process is straightforward and worthwhile. Here is an overview of the main steps that I typically follow:
1. Understanding Requirements and the Initial Consultation
First, you must clearly define what you need. I will work closely with you to understand your application, operating environment and any limitations. This could involve site visits, team meetings and detailed technical discussions. My goal is to become an extension of your own team and treat your problems as if they were my own. Some of the questions that I will ask include:
- What tasks will the panel PC be expected to handle?
- What are the environmental conditions like (temperature, humidity, dust and vibration)?
- How much processing power and memory do you actually need?
- What input/output (I/O) connections do you require, such as USB, Ethernet or serial?
- Are specific certifications needed, such as UL, CE or FCC?
- What screen size and resolution is ideal?
- What are the power requirements?
- What is your budget?
2. The Design and Engineering Phase
Once I have a complete understanding of your requirements, my engineering team begins the design process. This includes selecting components, designing the enclosure and developing the system architecture. I use current design tools and methods to make sure that everything performs as expected, is reliable and easy to manufacture.
During this phase, I develop detailed schematics, 3D models and simulations to evaluate the design and identify potential problems early. I also work with you to review the design and get your feedback. My approach is built around close collaboration. This ensures that you remain involved throughout the process.
3. Prototyping and Thorough Testing
Once the design has been finalized, I build a prototype of your custom panel PC. This allows us to test it in a real world environment to find any remaining issues or areas that could be improved. I subject each prototype to the following:
- Environmental Testing: To verify that the panel PC can handle the specified temperature, humidity and vibration.
- Performance Testing: To make sure that the panel PC has the required processing power and memory.
- Functional Testing: To verify that all I/O connections and other features are working correctly.
- Compliance Testing: To confirm that the panel PC meets all regulatory standards.
I provide a detailed test report and correct any problems that are found. I will not move forward until you are completely happy with the prototype.
4. The Manufacturing and Assembly Process
Once the prototype has been approved, I begin manufacturing and assembly. I have long established relationships with leading manufacturers and suppliers. This ensures high quality components at competitive prices. I maintain strict quality control throughout the entire manufacturing process to make sure that every panel PC meets my exacting standards.
I offer a variety of manufacturing options, from small batch to high volume production. I also provide custom packaging and labeling to meet your specific needs.
5. Integration and Ongoing Support
After manufacturing and assembly, I provide integration and support to help you deploy the panel PCs in your application. This includes:
- Software Installation and Configuration: Installing and configuring the operating system, drivers and any software that is required.
- Network Configuration: Configuring network settings so the panel PCs can communicate with your existing systems.
- On Site Installation: Providing on site installation services to deploy the panel PCs in your facility.
- Training: Training your staff on how to use and maintain the panel PCs.
- Ongoing Support: Providing support to resolve any problems that might arise.
Key Factors to Consider Before Starting Your Custom Panel PC Project
Before you start a custom panel PC design project, keep these points in mind:
1. The Environment Where It Will Operate
The operating environment will have a significant effect on your panel PC design. You must consider these factors:
- Temperature: What temperature range do you anticipate? Will the panel PC be exposed to extreme heat or extreme cold?
- Humidity: What is the humidity level? Will the panel PC be exposed to moisture?
- Dust: Is it a dusty environment? Will the panel PC be exposed to airborne particles?
- Vibration: Will the panel PC be exposed to vibration?
- Ingress Protection (IP) Rating: How much protection is needed from dust and water?
I once helped a food processing plant that needed a panel PC that could withstand frequent high pressure washdowns. I engineered a custom enclosure with a high IP rating to protect the internal components from water damage.
2. How Much Processing Power and Memory Are Needed
The processing power and memory that you need will depend on your application. You must consider these points:
- What software will the panel PC be running?
- How many applications will be running at the same time?
- How much data will it be expected to process?
- What level of performance is needed?
You must select a processor and memory configuration that is capable of handling the workload. I can help you choose the right components for your specific needs.
3. Input/Output (I/O) Interfaces
I/O interfaces determine how the panel PC connects to other devices. You must consider these aspects:
- What devices will be connected to the panel PC?
- What communication protocols do you need?
- How many I/O ports are needed?
- What are the power requirements for the I/O devices?
Common I/O interfaces include USB, Ethernet, serial, HDMI and DisplayPort. I will customize the I/O setup to meet your specific requirements.
4. Selecting the Right Display Size and Resolution
Display size and resolution are dictated by the application and the viewing distance. You must consider this:
- What information will the screen be displaying?
- What is the viewing distance?
- How much detail needs to be visible?
- Is a touchscreen needed?
I offer display sizes and resolutions ranging from small embedded displays to large industrial monitors. I also provide touchscreens that make use of resistive, capacitive and infrared technologies.
5. Power Requirements
Power needs are driven by the components that are used and the operating environment. You must consider these factors:
- What is the input voltage range?
- How much power will the system use?
- Is a battery backup needed?
- What type of power connector is required?
I can design the power supply to meet your needs and ensure dependable operation.
How OEM Panel PCs Fit Into Customization
OEM (Original Equipment Manufacturer) panel PCs provide a base for custom builds. You can modify these prebuilt units to meet your specific requirements. I often use them as a starting point. I take advantage of their existing features to save development time and money. Think of it as similar to a prefabricated home. It is easier to customize than building from scratch.
Here is how OEM panel PCs fit into the custom design process:
- Faster Development: Starting with a platform that is already in existence saves time on the initial design and component selection.
- Reduced Costs: Using existing manufacturing processes reduces costs, especially for smaller production runs.
- Proven Reliability: OEM panel PCs have already been tested. This provides a reliable base for customization.
- Concentrated Customization: This lets you focus on the features that are unique and the most critical.
I can modify OEM panel PCs by:
- Modifying the Enclosure: Changing the enclosure to meet specific size, shape or environmental requirements.
- Customizing I/O: Adding or removing I/O ports to support specific devices.
- Integrating Software: Installing software and drivers to optimize performance.
- Adding Branding: Adding your company logo.
Embedded System Design: The Core of Your Custom Panel PC
An embedded system is at the heart of every custom panel PC. It controls all device functions. Effective embedded system design is essential to any project. I have embedded system specialists who focus on custom solutions for a wide range of applications.
These are key aspects of embedded system design that I make a priority:
- Processor Selection: Choosing the right processor by considering performance, power consumption and cost. I select processors based on data, not marketing claims.
- Operating System Selection: Choosing the right operating system, whether it is a real time operating system (RTOS) for time sensitive performance or a general system like Linux or Windows.
- Driver Development: Developing drivers for devices that are not supported by standard drivers.
- Firmware Development: Developing firmware that controls how the system functions.
- Security: Putting security measures in place to protect the system from unauthorized access. I have a cybersecurity team that stays informed about new threats.
I have experience developing embedded systems for the following applications:
- Industrial Automation: Controlling machinery and robots.
- Medical Devices: Controlling medical instruments and monitoring a patient’s vital signs.
- Transportation: Controlling vehicle systems and managing traffic flow.
- Aerospace: Controlling aircraft systems and monitoring flight telemetry.
Examples of How Custom Panel PC Solutions Have Been Used
Here are a few examples of how tailored PC solutions have made a real difference:
- Automated Food Processing: I designed a custom panel PC for a food processor that was looking for a way to control its production line. The panel PC featured a touchscreen display. This made it easy for operators to monitor production and make adjustments. The system also included sensors to monitor temperature and humidity. This ensured safe processing conditions.
- Medical Imaging Device: I developed a custom panel PC for a medical device company that needed a high performance embedded system. The panel PC included a powerful processor and a high resolution display. This allowed doctors to view detailed medical images. The system also made use of advanced image processing algorithms.
- In Vehicle Computing: I created a custom panel PC for a transportation company that needed a rugged computer for its fleet vehicles. The panel PC was engineered to handle extreme temperatures, vibration and shock. It also included GPS and cellular communication capabilities. This allowed the company to track vehicles and communicate with drivers effectively.
Selecting the Right Partner for Your Custom Panel PC Design
The partner that you choose is key for your custom panel PC project. Look for a company that has:
- Extensive Experience: A long track record of designing and manufacturing custom panel PCs.
- Technical Expertise: Engineers who have experience in embedded systems, hardware design and software development.
- Design Capabilities: The ability to provide design services, from gathering requirements to prototyping and testing.
- Manufacturing Capabilities: Access to advanced manufacturing facilities.
- Support Services: Comprehensive support services that include integration, training and maintenance.
I pride myself on being a partner that can be trusted. I am dedicated to providing exceptional service to my clients. I understand that every project is different. I am committed to providing custom solutions that go above and beyond what you expect.
What the Future Holds for Custom Panel PC Design
I expect that the demand for custom panel PC design will continue to increase. As more industries make use of automation, the need for specialized computing solutions will become even more critical. I am constantly working on new ideas to meet the changing needs of my clients.
Here are some of the trends that I am seeing:
- A Need for Rugged Designs: As panel PCs are used in increasingly harsh environments, there will be a greater demand for designs that can handle extreme temperatures, vibration and shock.
- An Emphasis on Cybersecurity: As panel PCs connect to networks, there will be a greater need for strong security measures.
- Integration of Artificial Intelligence (AI): AI is being integrated into panel PCs to make possible predictive maintenance, anomaly detection and advanced machine learning capabilities.
- The Use of Advanced Display Technologies: New display technologies such as OLED and microLED are providing displays that are brighter and more energy efficient.
I am committed to staying on the leading edge of these advances and providing my clients with the best custom panel PC solutions.
So what is the takeaway? Custom panel PC design provides a way to optimize computing solutions for specific applications. By tailoring the design, from selecting components to the final construction, you can achieve better performance, greater reliability and easy integration. As technology continues to advance and industries become more specialized, the need for custom solutions will only grow. Please contact me to discuss your project and find out how I can help you to fully realize the potential of custom panel PC design.
