Rugged Water-Cooled Embedded Computer for Autonomous Defence Vehicles
A BVM CASE STUDY
Delivering High-Performance AI Computing for Next-Generation Uncrewed Military Platforms
Our customer is a globally recognised developer of autonomous defence vehicles, specialising in the design and manufacture of advanced uncrewed platforms for military applications. Their expertise combines sophisticated hardware – including sensors, processors, vehicle control systems, and actuation technologies – with complex software architectures that enable autonomous vehicles to operate, analyse their environment, and perform critical missions without direct human intervention.
As autonomous defence systems become increasingly reliant on real-time AI processing and edge computing, the onboard computer has become a mission-critical component, requiring exceptional performance, reliability, and environmental resilience.
Customer Requirements: High-Performance Edge AI Computing for Extreme Environments
The customer approached BVM to provide a rugged embedded computing solution capable of powering advanced autonomous vehicle workloads while operating reliably in some of the world’s most demanding environments. The system needed to deliver server-class processing performance within a compact, sealed, and military-ready platform capable of withstanding extreme temperatures, moisture, vibration, and harsh outdoor conditions.
Key System Capabilities
- Intel Core i7 processing: high-performance computing for autonomous vehicles
- NVIDIA L4 GPU acceleration: advanced AI inference and real-time data processing.
- Fanless rugged design: no moving parts to reduce maintenance.
- Waterproof construction: built for harsh military and outdoor environments.
- Wide 8V to 48V DC input: supporting flexible vehicle system integration.
- Reverse polarity protection: preventing damage from incorrect power connections.
- Integrated ignition control: seamless vehicle power management.
- Extreme temperature operation: reliable performance in challenging environments.
- Mission-critical reliability: long-term performance for autonomous defence deployments.
Meeting these requirements required more than an off-the-shelf industrial computer. A highly customised engineering approach was needed to overcome the thermal and environmental challenges of combining high-performance AI processing with rugged, sealed operation.
Engineering Challenge: Solving Thermal Management for Fanless AI Computing
The primary challenge was thermal management. Running a powerful Intel Core i7 processor alongside an NVIDIA L4 GPU inside a completely sealed, fanless enclosure creates significant heat output. Traditional passive cooling methods were unable to provide sufficient thermal performance under sustained high workloads, particularly in high-temperature operational environments.
To overcome this challenge, BVM worked closely with both the customer’s engineering team and Neousys engineers to redesign the thermal architecture of the system. Detailed thermal profiling was carried out, the standard heatsink solution was removed, and a bespoke liquid-cooling system was engineered to provide efficient heat transfer while maintaining the required sealed and rugged construction. This approach enabled the system to deliver maximum AI processing performance without thermal throttling, even during continuous operation in extreme environments.
BVM Solution: Customised Neousys SEMIL-2000GC Rugged Embedded Computer
BVM supplied a customised version of the Neousys SEMIL-2000GC rugged embedded computer, engineered specifically for deployment within autonomous defence vehicles. The SEMIL-2000GC provided the ideal foundation thanks to its rugged construction, environmental protection, and suitability for demanding mobile applications.
Key features of the customised solution included:
- Corrosion-resistant chassis built from stainless steel and aluminium, protecting against moisture and salinity in exposed field environments
- M12 rugged connectors, providing secure, shock- and vibration-resistant connections in mobile and high-vibration applications
- MIL-STD-810H compliance, confirming the system’s suitability for demanding military and defence-grade conditions
- Custom-engineered water-cooling integration, developed specifically to resolve the thermal challenges of running a high-performance CPU and GPU in a sealed, fanless enclosure
- Wide-temperature memory and storage, enabling stable fanless operation across a −40°C to 70°C range
The result was a rugged AI edge computer capable of combining exceptional processing power with the reliability required for autonomous military vehicle deployment.
Project Outcome: A Proven Computing Platform for Future Autonomous Defence Programmes
Following successful testing and validation, the customised water-cooled SEMIL-2000GC solution exceeded the customer’s performance and environmental requirements. The system was selected as the standard onboard computing platform for the customer’s autonomous vehicle programme, providing the processing capability required for advanced AI workloads, sensor processing, and autonomous decision-making.
By overcoming the thermal challenges of high-performance fanless computing, BVM delivered a mission-ready platform capable of operating reliably in extreme defence environments.
Partner with BVM for Rugged Embedded Computing Solutions
Whether you are developing autonomous vehicles, AI-enabled systems, industrial automation platforms, or mission-critical embedded applications, BVM has over 35 years of experience designing and supplying rugged computing solutions for demanding environments. From GPU-powered AI edge computers and vehicle-mounted systems to fully customised industrial platforms, our engineering team can help transform complex technical requirements into reliable, deployable solutions.
Contact BVM today to discuss your next rugged computing project.
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Contact BVM for all your Industrial and Embedded Computing OEM/ODM design, UK manufacturing or distribution needs. With over 35 years of experience, we supply standard hardware and design custom solutions tailored to your requirements.
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