Case Study: Edge Computing for Corrosion Monitoring in Extreme Mining Environments

Edge Computing for Corrosion Monitoring in Extreme Mining Environments
A BVM Case Study

Introduction to the Customer: Global Leader in Corrosion Monitoring Technology

BVM’s customer is a leading provider of innovative corrosion and erosion monitoring solutions, holding a critical role in asset integrity across high-value industrial sectors.

They specialise in the design and manufacture of advanced ultrasonic sensor technologies used within pipelines, vessels, and structural assets. Their technology delivers the real-time, high-precision data essential for predictive maintenance, ensuring the safety, longevity, and regulatory compliance of infrastructure in some of the world’s most challenging environments.

Critical Customer Requirements: Compact Power with Total Connectivity

The customer required a highly specialized embedded computer solution to act as the rugged edge gateway for their ultrasonic sensor network. The system had to meet three non-negotiable criteria:

• Ultra-Compact & DIN Rail Mountable: The PC needed a minimal footprint for easy, secure installation inside compact junction boxes and control cabinets common in mining infrastructure. The DIN rail mounting was crucial for rapid deployment and simple maintenance.
• Fanless Operation: To eliminate the risk of dust and moisture ingress, the design required 100% fanless operation to guarantee reliability and zero maintenance in dusty mining conditions.
• Total Wireless Connectivity: The computer needed the expandability to integrate essential industrial communication technologies—specifically Bluetooth, Wi-Fi, and 4G connectivity—to enable seamless, reliable, and real-time data transmission from the remote site back to central processing servers.

Challenge: Enduring the Extremes of the Mining World 🥶🔥

The primary challenge lay in the extreme operating environment of the mining application. The industrial computer had to withstand the severe and volatile conditions characteristic of both surface and underground operations:

• Extreme Temperature Swings: The unit needed to operate reliably within a massive temperature range, specifically -25°C to 70°C. Standard commercial-grade computers fail instantly under these thermal demands.
• Physical Rigour: The system required a rugged chassis and construction to absorb continuous vibration, shock, and mechanical stress from heavy machinery and dynamic operations found throughout the mining environment.
• Environmental Ingress: Dust, moisture, and potential corrosive agents necessitated a fully sealed, fanless design to ensure the longevity and continuous function of the embedded electronics.

Product Supplied by BVM: The Neousys POC-410 Ultra-Compact Gateway

To meet the stringent performance, size, and thermal requirements, BVM selected and configured the Neousys POC-410 ultra-compact fanless embedded computer.

The POC-410 was chosen for its ideal combination of rugged features and expansion capability:

• Processor: Equipped with an Intel Atom® x6425E Quad-Core processor, the unit provides exceptional computing performance for edge processing while maintaining the low thermal profile necessary for fanless cooling.
• Wide Temperature Resilience: The PC is engineered for -25°C to 70°C operation, perfectly matching the customer’s extreme environmental specifications.
• BVM Customisation: BVM further enhanced the solution’s resilience by installing wide-temperature industrial-grade memory and storage components, ensuring data integrity and system stability across the entire required thermal range.
• Expandability: The POC-410’s compact design includes the necessary internal M.2 and mPCIe slots, enabling BVM to seamlessly integrate the required Bluetooth, Wi-Fi, and 4G modules for complete, robust wireless communication.
• Physical Integration: Its ultra-compact form factor (designed specifically for DIN-rail mounting) ensured simple, space-saving deployment within the existing customer housing.

Result: Enhanced Reliability and Successful Phase Rollout

The custom-configured POC-410 solution provided the customer with a reliable, high-performance edge platform capable of operating 24/7 in the extreme conditions of the mining site.

• Uninterrupted Data Flow: The rugged fanless design and wide-temperature components ensured continuous operation for the corrosion monitoring sensors, providing uninterrupted real-time data acquisition and transmission.
• Scalable Success: The customer immediately recognized the system’s robust performance and ease of integration. They have successfully implemented a significant number of these units across their current infrastructure.
• Future Growth: Based on the successful deployment and field performance, the customer is now confidently planning the next phase of their rollout, confirming BVM’s solution as the trusted computing platform for their technology moving forward.

Powering Your Edge with 30 Years of Expertise

Whether your application demands fanless resilience in extreme temperatures or compact power for complex edge processing, BVM has the industrial computing expertise you need. With over 30 years of experience in configuring and supplying rugged embedded systems, we turn complex technical requirements into reliable, field-proven hardware solutions.

Don’t compromise on reliability. Contact BVM today to discuss your next industrial or embedded computer challenge.