IP67 Transportable Control Centre for Autonomous Underwater Vehicle Operations
A BVM Case Study
Customer Overview
A global developer of autonomous underwater vehicles (AUVs) required a rugged, transportable control centre for a new coastal and harbour surveillance application. The system would be used to remotely monitor and control unmanned underwater vehicles from a variety of challenging environments, including shore-based locations and high-speed rigid inflatable boats (RIBs).
Although the customer had significant in-house engineering expertise, their development teams were fully committed to existing AUV programmes. They required an experienced UK-based design and manufacturing partner capable of delivering a complete, production-ready solution within a demanding timescale.
BVM was selected to design, manufacture, test and certify a fully integrated portable control centre engineered specifically for harsh marine environments.
The Challenge
The project required much more than integrating a computer into a rugged enclosure. The system had to provide the performance of a fixed control station while remaining completely portable and capable of operating reliably in demanding maritime conditions.
Key requirements included:
- High-performance computing platform for mission-critical remote vehicle control
- 18.5-inch Full HD PCAP touchscreen with exceptional daylight readability
- Reliable operation aboard fast-moving RIB vessels and coastal environments
- IP67 protection against water, dust, salt spray and moisture
- Multiple waterproof I/O connections, including HDMI for external display support
- AC and DC power compatibility for flexible field deployment
- Advanced thermal management without compromising enclosure sealing
- Compliance with IP67 and EN 60529 ingress protection standards
- Prototype delivery within just 10–12 weeks
Delivery of the first prototype was required in a relatively short timescale (10 -12 weeks).
The Design
Working closely with the customer, BVM engineered a bespoke transportable control centre built around a custom-machined Pelicase® enclosure. Every component was selected and integrated to maximise reliability, portability and long-term operation in harsh marine environments.
High-Brightness Display
At the heart of the system is an 18.5-inch Full HD (1920 × 1080) industrial display featuring:
- 1,000-nit LED backlight for excellent sunlight readability
- Projected capacitive multi-touch technology
- Wide viewing angles for operation in varying environments
The display allows operators to maintain clear visibility whether deployed on land or aboard moving vessels.
High-Performance Embedded Computing
The control centre is powered by an industrial 3.5-inch single board computer featuring an Intel® Core™ i7-8665UE processor. Supporting hardware includes:
- 16GB industrial wide-temperature DDR4 memory
- 1TB industrial-grade MLC mSATA SSD with integrated power-loss protection
- Custom Windows 10 IoT operating system image optimised for reliable field deployment
The platform delivers the computing performance required for real-time monitoring, communications and remote vehicle control.
Advanced Thermal Design
Maintaining performance inside a sealed IP67 enclosure required an innovative cooling solution.
BVM designed a custom copper and aluminium heatsink that mounts directly to the embedded computer. The heatsink extends through the base of the Pelicase, exposing cooling fins externally while maintaining complete enclosure sealing. This passive cooling architecture eliminates the need for fans, significantly improving reliability while enabling continuous operation across a wide operating temperature range.
Rugged Marine Construction
Every aspect of the enclosure was engineered for harsh maritime environments. Features include:
- Custom sealed aluminium display bezel: This feature ensures that the display is protected from environmental elements while maintaining a sleek appearance.
- Waterproof connector system for all external interfaces: The waterproof connector system provides reliable connections, safeguarding against moisture and enhancing durability.
- Network, fibre and HDMI connectivity: Sealed industrial connectors facilitate seamless network, fibre, and HDMI connections while preventing water intrusion.
- Embedded EMC protection using a dedicated aluminium electronics enclosure: The dedicated aluminium enclosure offers embedded electromagnetic compatibility (EMC) protection, minimizing interference and enhancing performance.
- Fully sealed cable penetrations to preserve IP67 integrity: Fully sealed cable penetrations help to maintain IP67 integrity, ensuring devices remain waterproof and dustproof.
- Integrated 150W DC power supply supporting both AC and DC operation: The integrated power supply supports both AC and DC operation, providing versatility and reliability for various applications.
The result is a highly durable portable control station designed to withstand water ingress, salt exposure, vibration and demanding operational conditions.
Testing and Certification
Following manufacture, the complete system underwent extensive environmental and compliance testing. The transportable control centre successfully achieved:
- IP67 ingress protection certification ensures devices are dust-tight and can withstand immersion in water up to 1 meter for 30 minutes.
- EN 60529 compliance guarantees that the equipment meets the European standard for degrees of protection provided by enclosures against moisture and solid objects.
- Conducted and radiated EMC emissions testing verifies that the device meets regulatory requirements for electromagnetic compatibility, preventing interference with other devices.
- Electromagnetic susceptibility testing assesses the device’s ability to operate without malfunction in the presence of electromagnetic interference.
- Thermal chamber validation across an operating range of -20°C to +50°C confirms that the equipment operates effectively and reliably within specified temperature limits.
These tests verified reliable operation in the demanding environments expected during coastal surveillance missions.
The Result
BVM delivered a fully integrated, production-ready portable control centre that exceeded the customer’s technical and environmental requirements. The completed system provides:
- Rugged IP67-rated protection against harsh marine environments ensures longevity and reliability in extreme conditions.
- High-performance industrial computing for autonomous underwater vehicle operations enables advanced data processing during underwater missions.
- Exceptional outdoor touchscreen visibility allows for easy operation in bright sunlight.
- Reliable passive cooling without compromising enclosure integrity maintains optimal performance even in demanding environments.
- Complete customer-specific waterproof connectivity provides tailored solutions for diverse marine applications.
- Flexible AC and DC power operation offers versatility for various power sources in marine settings.
- Proven compliance with marine environmental and EMC standards guarantees the device meets rigorous industry regulations.
Today, the transportable control centre provides operators with a robust, reliable and highly portable platform for controlling autonomous underwater vehicles during harbour security, coastal surveillance and other demanding maritime applications.
Looking for a Custom Rugged Computing Solution?
BVM specialises in designing and manufacturing bespoke industrial computer systems for harsh and mission-critical environments. From portable control centres and rugged HMI solutions to fully customised embedded computers, our engineering team can develop solutions tailored to your exact application requirements.
Whether your project requires IP-rated protection, advanced thermal management, custom I/O, or industry-specific certifications, BVM has the expertise to deliver reliable, production-ready systems engineered for the most demanding environments.
Ready to Discuss Your Project?
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.
Reach our expert sales team on 01489 780144 or email us at sales@bvmltd.co.uk.