The Challenge
A client in the metalworking industry was using standard desktop computers to control their CNC milling machines. The problems were frequent and costly:
Oil mist and metal dust
The fans sucked in coolant fluids and metal particles, causing short circuits on the motherboard.
Machine vibrations
Constant vibrations dislodged RAM modules and SATA cables, causing random crashes and data loss.
Lack of legacy ports
Modern desktop PCs do not have RS-232/485 ports for connecting to older PLC controllers and CNC control units.
Unplanned downtime
Every hardware failure stopped the production line for hours, leading to losses of thousands of pounds.
The IWILL Solution
We deployed the IBOX Series (Fanless Box PC) with an Intel Core i5 processor, designed specifically for factory automation:
Fully sealed aluminium design
Passive cooling via an aluminium heatsink eliminates fans and ventilation openings. There is no way for oil mist, swarf or dust to penetrate inside. The entire body of the computer acts as one solid heatsink.
Vibration and shock resistance
Industrial design with no moving parts – no HDD, no fans. The M.2 SSD is fixed directly to the board. On certain models, the RAM is soldered, eliminating the risk of loosening.
Built-in RS-232/485 COM ports
Up to 6x serial COM ports (RS-232/RS-485/RS-422) for direct communication with the CNC controller, PLC modules and SCADA systems. No need for USB-to-Serial adapters that lose connection.
DIN Rail & wall mounting
Compact enclosure with a DIN Rail clip for mounting inside the electrical cabinet, right next to the CNC controller. Saves space and shortens cable runs.
Result
Zero hardware failures over the past 24 months and full compatibility with the machine control software. The client eliminated unplanned downtime related to computer hardware and significantly reduced IT maintenance costs on the factory floor.
