Designing electronics today can be complex. Computers, phones, and other devices need to be able to do a lot in a small package. Meeting these increased functional requirements while protecting against high heat, low freezing and other harsh environments is more challenging.
Although difficult, many modern electronic devices operate in harsh industrial or outdoor environments. Some even work in outer space or in the depths of the oceans
It starts with determining the factors the device must withstand. Once engineering teams know what usage environments look like, they address each risk through several material and design choices.
Protection from extreme heat
High temperatures are among the most common extremes that a computer must face. Factories and outdoor spaces get hot, but the heat can lead to electrical overloads and battery failure. Designers address this risk in two primary ways: cooling and low-power components.
Traditional computers often use fans to keep them cool. Powerful alternatives usually used liquid cooling, as water did
Low-energy components are another piece of the puzzle. Normally, things like CPUs generate a lot of heat because they use a lot of power. Newer, lower-power versions produce lower temperatures from the start, so cooling systems don’t have to work as hard. Refractory materials such as gallium nitride are another promising alternative.
Keep cold
Extreme temperatures on the other end of the spectrum can cause problems as well. Although moderate cold is good for computers, very low temperatures can lead to condensation inside the device and cause problems with moving parts. The capacity of the lithium-ion battery also decreases at low temperatures, which is why electric cars lose
Insulation is the best line of defense against this danger. Foam or silicone insulators can retain the natural heat of electronic components so they remain at safe operating temperatures. Reducing open air vents can also help, although this is difficult if the device must also operate in warmer conditions.
Material choices also play a role. Military-grade alloys are less likely to warp amid temperature fluctuations, and OLED displays won’t freeze up like LCD displays. Some cold-weather electronics avoid components such as drives and fans to prevent problems with moving parts.
Prevent intrusion
Intrusion of dust, water, or other foreign objects and particles is another concern in harsh environments. Protection from this danger depends largely on sealing sensitive parts from the outside. Manufacturers often follow a metric called an Ingress Protection (IP) rating to determine how well they do this.
IP ratings consist of two numbers, the first indicating resistance to solid contaminants and the latter indicating protection against liquids. Each increases two points in IP rating
Electronics designed for harsh environments meet high IP ratings, completely insulating their components from dust and water. As impressive as this is, it is often relatively simple. The design simply encapsulates vulnerable parts in a tightly sealed container.
Surviving physical trauma
Computers in harsh industrial or environmental environments must also be able to withstand physical shock. Crashes, vibrations, drops, and other impacts can break small components, but a thoughtful choice of materials and cushioning can keep them safe.
Metals and advanced composites are preferred over plastics because they are less brittle. Placing components in a more compact and balanced arrangement can also help, as uniformity of electronic mass makes breakage less likely and dampens vibrations. Cushioning to distribute the force of an impact, often through rubber or reactive foam, provides an additional layer of protection.
In some cases, devices must withstand physical pressure from multiple angles. Manufacturers explain this by placing the main parts in a protective casing. These containers are often spherical in shape
Anti-electromagnetic interference
Electromagnetic interference (EMI) is another challenge. All electronics emit some amount of EMI, and this radiation is more prevalent in space, where there is no atmosphere to neutralize it. These energy waves can interfere with device functions, especially communication features, so it is important to protect against them.
Consumer Appliance Certifications
Grounding the electronic circuit also helps, as it moves excess electrical energy away from the device to prevent electromagnetic waves from escaping. Keeping high-power components in the center of the circuit board, adding capacitors to absorb excess power, and reducing the length of the electrical conduit can also help.
Designing computers for harsh environments requires a lot of planning
Doing a computer job in a demanding environment requires careful attention to detail and rigorous testing. Designers must anticipate the types of risks their devices will encounter and follow best practices to account for these risks. Even after proper planning, it usually takes some real-world testing and redesign to get things right.
As technology advances, it becomes easier to build more powerful electronics. New materials and more efficient operating components mean manufacturers can protect against the elements with fewer additional systems. With so much research providing so many options, there are relatively few situations for which modern hardware design cannot prepare.