Virtual Machines vs Physical Systems: Which Architecture Suits Your Application?

Virtual Machines vs Physical Systems: Which Architecture Suits Your Application?

Virtual Machines vs Multiple Physical Systems: Choosing the Right Hardware Strategy for Industrial Applications

In industrial and embedded computing, choosing between running multiple operating systems and workloads on one powerful system using virtual machines (VMs) or using multiple dedicated physical systems is a critical decision. Each approach has distinct advantages and limitations, depending on the application, performance needs, scalability, and environment.

This article compares both strategies with real-world examples, outlines their pros and cons, and explores use cases across various industrial sectors.

Virtual Machines vs Physical Systems: What’s the Difference?

Virtual machines allow multiple operating systems and workloads to run on a single physical computer, sharing the same hardware through virtualization. In contrast, multiple physical systems each run independently with their own hardware resources, operating systems, and roles.

Pros and Cons of Virtual Machines

✅ Advantages of Virtual Machines

  • Efficient Hardware Utilisation: Maximise the performance of high-end components by running several workloads on one system.
  • Scalability: Quickly spin up new VMs as needed without purchasing new hardware.
  • Cost-effective: Reduce software, hardware, power and cooling costs.
  • Simplified Management: Manage all systems from a central interface.

❌ Disadvantages of Virtual Machines

  • Resource Contention: Multiple VMs can compete for the same resources, leading to performance issues.
  • Complex Setup: Requires knowledge of virtualization platforms and maintenance of virtual environments.
  • Single Point of Failure: If the host system fails, all VMs go offline.

Pros and Cons of Multiple Physical Systems

✅ Advantages of Multiple Systems

  • Performance Isolation: No shared resources means more consistent performance for demanding applications.
  • Improved Redundancy: One system can fail without affecting the others.
  • Custom Hardware Per Task: Tailor each system with specific CPUs, GPUs, or storage based on workload.

❌ Disadvantages of Multiple Systems

  • Higher Costs: More systems mean more hardware, energy use, and potential licensing costs.
  • Space and Maintenance: Larger footprint and more points of failure to manage.
  • Less Flexible: Scaling up requires physical installation and setup of additional machines.

Real-World Examples: One System vs Multiple

1. AI Development Environment

AI Development Environment
  • Single System: One powerful workstation running both Linux and Windows VMs to manage AI training, development, and testing environments.
  • Multiple Systems: Two mid-range PCs (one Linux, one Windows) with dedicated workloads and consumer GPUs for cost-effective performance.

Verdict: A single system may save space and cost for light development; multiple systems offer better stability for concurrent, intensive use.

2. Simulation and Training

Simulation and Training
  • Single System: Intel Xeon or AMD Threadripper workstation with a professional RTX A6000 card running multiple simulation environments as VMs.
  • Multiple Systems: Two Intel Core i9 gaming PCs with NVIDIA RTX 4070s, each running individual simulations natively.

Verdict: For highly accurate, demanding simulations, pro hardware in a single system excels. For parallel training sessions or team use, multiple PCs may offer more flexibility.

3. Factory Automation

Factory Automation
  • Single System: Server running 10 – 20 VMs to control sensors, robotics, and databases across a factory floor.
  • Multiple Systems: Edge network of small embedded PCs at each station performing local control tasks and reporting back to a central server.

Verdict: VM-based servers offer centralized control and ease of updates. Edge devices provide low-latency performance and system redundancy.

4. Retail POS and Inventory Management

Retail POS and Inventory Management
  • Single System: Rack-mounted server at HQ running VMs for multiple branch systems, POS terminals, and databases.
  • Multiple Systems: Each branch has its own local system managing POS and inventory independently.

Verdict: VM approach is cost-effective and centralized, ideal for connected locations. Separate systems are better where connectivity is unreliable.

Edge Devices vs Virtual Machines vs Cloud

Choosing between edge computing, VMs, and the cloud depends on application needs:

  • Edge Computing: Real-time processing near the data source; ideal for time-sensitive industrial control, robotics and IoT.
  • Virtual Machines: Localized workloads with scalability and flexibility; great for environments needing multiple OS or workloads on a single device.
  • Cloud Computing: Ideal for globally distributed data, backups, or services where latency isn’t critical — less suitable for real-time industrial tasks.

Application Areas

Virtual machines and multiple physical systems are used in a wide range of industrial and embedded environments:

  • Manufacturing & Automation – Control systems, vision inspection, robotics
  • AI & Machine Learning – Model training, inferencing, and testing
  • Simulation & Digital Twin – Industrial simulation environments, R&D testbeds
  • Retail & Logistics – POS terminals, stock tracking, and order processing
  • Healthcare & Imaging – Medical diagnostics, imaging systems, and data processing
  • Transportation & Traffic Control – Real-time monitoring, video analytics, and predictive maintenance
  • Energy & Utilities – SCADA systems, monitoring stations, and distributed control

Need Help Choosing the Right Approach?

Contact us for all your Industrial and Embedded Computing needs. Whether you’re deciding between virtualisation or multiple systems, we’re here to help.

📞 Call our sales team on 01489 780144 or 📧 Or email us at sales@bvmltd.co.uk

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With over 35 years’ experience supplying Industrial and Embedded Computer hardware, we’ll find or design the right solution. If an off-the-shelf option doesn’t exist, our in-house design team can create one tailored to your application.

Need Help? Talk to an Expert!

At BVM, we don’t just supply products, we deliver comprehensive computing solutions tailored to suit our customers unique requirements. With over 35 years of expertise in the industry, our dedicated sales team is ready to help you select the perfect rugged, industrial or embedded hardware for your next project.

We supply a wide and diverse range of Industrial and Embedded Systems. From Industrial Motherboards, SBCs and Box PCs, to Rack Mount computers and Industrial Panel PCs. If you can’t find an “off-the-shelf” solution that fits, our in-house design team is at your service to craft a customised solution that exceeds your expectations.

You can Call us on 01489 780 144 and talk to a member the team, E-mail us at sales@bvmltd.co.uk or use our quick contact form.

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