The Key Differences Between Consumer and Industrial Hardware Development

The term “industrial electronics” refers to any electrical equipment or system used for manufacturing goods or participating in this process indirectly. Such electronics include, but are not limited to, measurement, monitoring, and control systems, battery management systems, industrial automation equipment, motor drives, etc. 

Industrial hardware development follows the same basic principles as consumer or commercial systems design. However, industrial equipment performs very specific functions and works in harsher conditions. As a result, it requires a more deliberate design approach.

Key Features of Industrial Hardware Development

1. Reliability

If industrial equipment fails, it can disrupt the work of the whole production line. Also, industrial equipment is expected to work for much longer without repair. This dictates the choice of better materials, higher-grade components for the PCBs, more durable coatings, etc. It also makes industrial hardware development more expensive. 

2. EMI and overvoltage protection

When designing consumer electronics, engineers provide devices with a certain level of EMI protection. But technologies we use in everyday life rarely face high levels of noise. Unlike them, the power supply circuits in industrial hardware must be designed in such a way as to suppress strong electromagnetic noise. Electronics used for industrial applications must also have higher overload capacity. Hence the need for additional EMI and overvoltage protection, which adds to the board’s cost.

3. Environmental hazards

Equipment used in manufacturing usually functions in harsh environmental conditions: vibration, physical shock, high temperatures, humidity, dust, chemicals, etc. To provide protection, engineers make boards thicker, use specific PCB geometries, install vibration dampers, coolers, and heaters to maintain a certain temperature, etc. Fluid-tight housings rated IP67 and higher can protect the board from water and humidity. Heavy components can be fixed on the board with screws to cope with vibration.  

Another option is to protect the PCB with conformal coating or encapsulation resin. Both of them are organic polymers that provide electrical insulation and offer some thermal and chemical resistance. However, their protection levels differ.

4. Thermal management 

Industrial equipment must function as long as possible without repair or replacement. Therefore, it must be heat-resistant: the higher the temperature, the faster electronic components degrade. Engineers use industrial-grade components that can withstand a wider range of temperatures. If such components are unavailable or not efficient enough, one should also use elaborate cooling systems consisting of large heat sinks, heat pipes, fans, thermal gap fillers, metal casing, and other means. Naturally, it makes devices more complicated and expensive but enhances their life span.

5. Sensors and controllers

Sensors and outputs in industrial solutions must be more reliable than their consumer-grade alternatives. Otherwise, the CPU may send the wrong command making the device do something it is not supposed to. This can lead to serious malfunctions, failures, and ultimately stoppage in production.

Commonly Used Industrial Solutions

With the wide use of robotics in industrial automation, the need for systems based on artificial intelligence cannot be overestimated. Computer vision and optical scanners are used in quality control systems, counting systems on production lines, as well as for automated grading and sorting. AI is an integral part of systems capable of damage recognition and assessment, automated guided vehicles (AGV) systems, etc. Voice recognition can be used in search systems, voice-controlled authentication, and navigation in vehicles. Many complex predictive maintenance and failure modeling systems use AI and machine learning. 

The use of the Internet of Things for manufacturing simplifies the work of the personnel making it easier to gather information from different points around the plant. It is not surprising that the global industrial IoT market was estimated at $263 billion in 2021. Industrial IoT solutions allow for uniting various sensors and/or beacons into a single network. IoT is used in remote equipment and asset monitoring systems, asset, fleet, and vehicle tracking solutions, on-field workforce management, predictive maintenance, and data security. 

Augmented and virtual reality technologies can provide immersive employee training. Cloud computing allows for storing and processing large amounts of data from sensors and equipment. Various power electronics solutions including battery management and battery energy storage systems can make energy consumption more efficient.

Key Information for Industrial Hardware Development

When ordering custom hardware development, it is crucial to provide the developers with all the information about the future device or system.

1. Functional Requirements 

These requirements describe the functions of the future device. It is also important to inform the team about the size, weight, power consumption, and similar characteristics if they are important.

2. Operating conditions 

Industrial solutions always operate in non-standard conditions, so it is crucial to inform the team about them. At the very least, the developers must know about the temperatures, humidity, and vibration levels the device will face.

3. Industry-specific requirements

Certain requirements may come from industry-specific standards and regulations. For example, devices used in the oil and gas industry must comply with fire safety requirements. For other industries, the team may need to reduce the electromagnetic noise coming from the hardware, etc. 

4. Testing and certification requirements

Any industrial hardware must comply with various certification standards and pass corresponding tests. It is a good practice to consult a certification body to learn about these requirements before ordering custom electronics development. This way, customers can provide the team with a list of specifications and parameters the future device must correspond to.

Industrial Electronics Certification

When designing new equipment, it is important to understand what certifications and testing procedures the device will have to pass. Here are some common certifications and standards industrial electronics may have to comply with:

• FCC
• CE Marking
• RoHS 2 Directive
• ASTA
• ANSI/CAN/UL 9540
• UL
• IECEx
• NFPA 70 ®
• ETL Mark

There are many more standards and certifications in each particular country and/or industry. 

Engineers must take into account all these and other factors during industrial hardware development. Since such equipment requires more durable components and a more considered design approach, creating industrial-grade systems is often more expensive compared to consumer electronics design. Therefore, manufacturers need to find experienced teams to do the job.

Also published here.