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How Do Manufacturers Use Industrial Computers for Digital Transformation?
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How Do Manufacturers Use Industrial Computers for Digital Transformation?

2026-07-14
Table of Contents


Introduction

Factory managers, automation engineers, IT/OT teams, machine builders, and system integrators face the same problem: production equipment generates valuable data, but much of that data remains locked inside separate machines.
A plant may have CNC machines purchased at different times, PLCs from several suppliers, testing equipment that communicates through serial ports, and new production systems connected through Ethernet. Operators may still record output, downtime, or inspection results manually.
This creates several problems:
  • Production managers cannot see real-time machine status.
  • Maintenance teams respond after equipment has already failed.
  • MES platforms cannot receive complete production data.
  • Quality records are stored in separate systems.
  • Old equipment cannot communicate directly with cloud platforms.
  • Data from different production lines uses inconsistent formats.
  • Digital transformation pilots cannot easily scale across the factory.
The business pressure is also increasing. According to Deloitte’s 2025 Smart Manufacturing and Operations Survey, 92% of surveyed manufacturing leaders believed smart manufacturing would be the main driver of competitiveness during the following three years. The same research found that 78% were allocating more than 20% of their improvement budgets to smart manufacturing initiatives.
Rockwell Automation’s 2025 State of Smart Manufacturing findings reported that 81% of manufacturers said internal and external pressures were accelerating digital transformation. It also found that 95% had invested in, or planned to invest in, AI and machine learning within five years.
However, digital transformation does not begin with AI software or a cloud subscription. It begins with reliable access to production data.
Industrial computers provide the computing, connectivity, and application layer needed to turn isolated equipment into connected production assets.
 
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What Role Do Industrial Computers Play in Manufacturing Digital Transformation?

An industrial computer acts as a bridge between physical production equipment and digital management systems.
A typical manufacturing data flow looks like this:
Machines, sensors, cameras, and robots
↓
PLCs, CNC controllers, motion controllers, and testing equipment
↓
Industrial computer or industrial edge computer
↓
HMI, SCADA, MES, database, or local analytics
↓
ERP, cloud platform, digital twin, or enterprise reporting system
Industrial computers in manufacturing usually perform four main functions.

  1. Data Acquisition

Industrial computers collect information from:
  • PLCs
  • Temperature, vibration, pressure, and current sensors
  • CNC machines
  • Industrial cameras
  • Barcode and RFID readers
  • Robot controllers
  • Weighing equipment
  • Test and measurement instruments
  • Energy meters
  • Quality inspection devices
Depending on the equipment, connections may use Ethernet, USB, RS-232, RS-485, CAN, GPIO, PoE, or an industrial expansion card.

  1. Edge Data Processing

Sending every raw data point or camera image to the cloud is not always practical.
An industrial edge computer can filter, organize, calculate, and analyze data near the machine. It can then send selected results to MES, ERP, or cloud platforms.
Local processing is useful when the application requires:
  • Fast response times
  • Continuous operation during network interruptions
  • Reduced cloud bandwidth
  • Local image processing
  • Sensitive production data control
  • Immediate alarms or machine actions

  1. System Integration

Factories often operate with equipment from different suppliers and different generations. Industrial computers can host middleware, protocol-conversion software, data connectors, or custom applications that normalize data before sending it to another system.
This allows industrial computers to support communication between:
  • Machines and SCADA
  • PLCs and databases
  • Production lines and MES
  • MES and ERP
  • Edge applications and cloud platforms
  • Old serial devices and modern Ethernet networks

  1. Industrial Application Hosting

Industrial computers can run applications such as:
  • HMI software
  • SCADA clients
  • MES terminals
  • Machine vision software
  • AI inference applications
  • Equipment monitoring software
  • Data-logging programs
  • Local databases
  • Remote maintenance tools
  • Digital work instructions
Factory layer Typical equipment Role of the industrial computer
Equipment layer Sensors, machines and cameras Collect operating and process data
Control layer PLCs, robots and CNC controllers Exchange status information and commands
Edge layer Industrial computer Process, store, filter and normalize data
Operations layer HMI, SCADA and MES Display, control and manage production
Enterprise layer ERP, cloud and analytics Support planning and business decisions


Why Do Manufacturers Use Industrial Computers Instead of Commercial PCs?

A commercial computer may work in a clean office, but production environments create different hardware requirements.
Factories may expose computers to dust, vibration, electrical interference, temperature changes, limited installation space, and continuous operating schedules. They may also require interfaces that are uncommon on consumer computers.
Requirement Industrial computer Commercial computer
Operating schedule Designed for industrial workloads and long operating cycles Mainly designed for office or personal use
Cooling Fanless and active-cooling models available Commonly relies on consumer cooling designs
Industrial interfaces May include COM, CAN, GPIO and multiple LAN ports Usually focuses on standard consumer ports
Expansion PCIe, PoE, frame grabber and I/O card options Expansion varies and may be limited
Installation Wall, DIN rail, rack, panel or machine mounting Usually desktop-oriented
Platform lifecycle Industrial platforms may remain available longer Models can change frequently
Power input DC and wide-voltage options available on selected models Commonly uses standard AC adapters or power supplies
Environmental design Selected models support wider temperatures and vibration resistance Usually specified for controlled environments
Customization I/O, enclosure, BIOS and system-image options may be available Limited project-level customization
This does not mean that every industrial computer is waterproof, fanless, wide-temperature, or shock-resistant. These capabilities depend on the selected model.
Manufacturers should always match the hardware specification to the real operating environment instead of assuming that all industrial computers offer the same protection.
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How Do Manufacturers Use Industrial Computers for Digital Transformation?

  1. Real-Time Production Monitoring and OEE Analysis

One of the first digital transformation projects in many factories is real-time production monitoring.
Industrial computers collect machine status, cycle time, output, alarms, downtime, and quality information. The data can be displayed on a local dashboard or transferred to SCADA and MES platforms.
A typical data flow is:
PLC or machine controller → industrial computer → SCADA or MES → production dashboard
This allows production teams to answer questions such as:
  • Which machines are currently running?
  • Which line has stopped?
  • What caused the downtime?
  • Is actual cycle time higher than the target?
  • How many products were completed during the shift?
  • What is the current OEE?
  • Where is the production bottleneck?
Industrial computers reduce dependence on manual records and help managers make decisions using current production data rather than end-of-shift reports.
Manufacturers planning this type of project can also review the SINSMART guide to choosing an industrial PC for CNC machine monitoring.

  1. Connecting Legacy Machines to Digital Systems

Digital transformation does not always require replacing old production equipment.
Many legacy machines still operate reliably but lack a direct connection to MES, SCADA, or cloud platforms. Some use RS-232 or RS-485, while others depend on proprietary controllers or older software.
An industrial computer can serve as a data collection and conversion node between the machine and a modern digital system.
Legacy equipment Possible connection Digital destination
CNC machine Ethernet or serial communication MES or machine-monitoring platform
PLC Ethernet, RS-485 or expansion interface SCADA or database
Testing machine USB, COM or data acquisition card Quality management system
Barcode reader USB or serial connection Traceability database
Industrial camera GigE, USB or PoE Machine vision application
Energy meter RS-485 or Ethernet Energy management platform
Common protocols may include Modbus RTU, Modbus TCP, OPC UA, or MQTT. However, compatibility depends on the machine protocol, controller, driver, software, and available interfaces.
An industrial computer does not automatically make every old machine compatible. Engineers should audit the equipment before choosing the hardware.

  1. Predictive Maintenance and Condition Monitoring

Traditional maintenance is often reactive or based on fixed schedules.
Reactive maintenance begins after a failure. Scheduled preventive maintenance may replace parts before they are actually worn. Predictive maintenance uses operating data to identify changes that may indicate a future problem.
Industrial computers can collect data from:
  • Vibration sensors
  • Temperature sensors
  • Current sensors
  • Acoustic sensors
  • Pressure sensors
  • Oil-quality sensors
  • Machine alarms
  • Maintenance records
The industrial computer may preprocess the information locally, calculate trends, detect abnormal behavior, and send alerts to a maintenance platform.
A basic workflow is:
  1. Sensors collect equipment-condition data.
  2. The industrial computer receives and organizes the data.
  3. Local software compares the data with normal operating conditions.
  4. The system identifies unusual changes.
  5. Maintenance personnel receive an alert.
  6. Inspection can be scheduled before a major failure occurs.
For standard condition monitoring, a low-power fanless industrial PC may be sufficient. More complex analytics may require a higher-performance processor, additional memory, or local AI acceleration.

  1. Machine Vision and Automated Quality Inspection

Machine vision is one of the most valuable applications of industrial computers in manufacturing.
An industrial computer can connect to one or more cameras, receive images, run inspection software, store results, and send pass-or-fail signals to a PLC, robot, or sorting mechanism.
Common machine vision tasks include:
  • Surface-defect detection
  • Dimension measurement
  • Component positioning
  • Optical Character Recognition (OCR)
  • Barcode reading
  • Product classification
  • Assembly verification
  • Label inspection
  • Automated sorting
  • Production traceability
For example, a vision system may inspect a component immediately after assembly. The industrial computer analyzes the image, records the result, and sends a rejection signal if the component does not meet the inspection rules.
Hardware selection depends on the number of cameras, resolution, frame rate, interface bandwidth, inspection software, and response-time requirement.
Vision workload Important hardware requirement
Single-camera inspection Suitable CPU and camera interface
Multiple GigE cameras Sufficient LAN bandwidth and independent ports
PoE camera system PoE ports or an expansion card
AI defect detection GPU, NPU or other AI acceleration
High-resolution image storage Fast SSD and sufficient capacity
Real-time sorting Low-latency processing and reliable I/O
SINSMART provides configurable machine vision computer solutions for applications ranging from barcode reading to more complex image recognition.

  1. MES, SCADA and ERP Integration

A common misunderstanding is that an industrial computer replaces MES, SCADA, or ERP.
It normally does not.
Instead, the industrial computer supplies the reliable field-level computing and connectivity that these systems need to receive production data.
System Main function Role of the industrial computer
HMI Local operator interaction Runs or connects the operator interface
SCADA Supervisory monitoring and control Supplies real-time equipment data
MES Production execution and traceability Connects machine events with work orders
ERP Enterprise resources and planning Receives summarized production information
Cloud platform Centralized analytics and multi-site management Receives selected edge data
For example, an industrial computer can read production counts from a PLC, associate them with an MES work order, store data locally during a network interruption, and synchronize the records when the connection is restored.
This architecture helps manufacturers avoid incomplete records and reduces manual data entry.

  1. Edge Computing and Local AI Inference

Cloud computing is useful for large-scale storage, centralized management, model training, and analysis across multiple factories. However, cloud platforms may not provide the response time needed for every production task.
Industrial edge computers process time-sensitive data near its source.
Edge processing is especially useful for:
  • Real-time quality inspection
  • Machine-condition alerts
  • Local process optimization
  • Image and video analysis
  • Production-line control support
  • Network-limited factories
  • High-volume sensor data
  • Sensitive production information
Cloud platforms remain useful for:
  • Long-term trend analysis
  • Enterprise reporting
  • Cross-factory comparisons
  • Centralized application management
  • AI model training
  • Large-scale data storage
Manufacturers therefore do not usually need to choose only edge or only cloud. A practical architecture processes urgent data on industrial computers and transfers selected information to enterprise or cloud systems.
Siemens describes industrial edge computing as a way to support IT/OT integration, OEE monitoring, intelligent maintenance, production analytics, AI defect detection, and shop-floor-to-cloud connectivity.

  1. Product Traceability and Digital Quality Records

Traceability is important in automotive, electronics, food, pharmaceutical, medical equipment, and other regulated or quality-sensitive industries.
An industrial computer can connect to:
  • Barcode scanners
  • RFID readers
  • Cameras
  • Label printers
  • Scales
  • PLCs
  • Test equipment
  • MES databases
The system can record:
  • Raw material batch
  • Product serial number
  • Production time
  • Machine or production line
  • Operator
  • Process parameters
  • Test results
  • Inspection images
  • Packaging information
  • Final quality status
These records make it easier to investigate quality problems, locate affected batches, and reduce the time required to complete a product recall.
For a sector-specific example, see the SINSMART guide to using an industrial PC for food and beverage production lines.

  1. Remote Monitoring, Energy Management and Digital Twins

Industrial computers can also support remote equipment monitoring.
Authorized engineers may use the system to:
  • View machine status
  • Check alarms and logs
  • Update approved software
  • Diagnose equipment problems
  • Manage multiple production sites
  • Reduce unnecessary service visits
For energy-management projects, industrial computers can collect electricity, water, gas, steam, or compressed-air data. Manufacturers can then compare energy consumption by machine, line, shift, or finished product.
Industrial computers can also supply data to a digital twin platform. The industrial computer collects and normalizes real machine data, while the digital twin represents the condition or behavior of the physical asset.
The industrial computer itself is not the complete digital twin. It is one part of the data and computing infrastructure that keeps the digital model connected to the physical system.


Example: Connecting a Legacy Production Line to MES

Consider a production line with several older machines. The equipment can output operating data through RS-485, but operators still record production quantities and downtime manually.
The factory wants to connect the line to its MES without replacing the machines.

Existing Problems

  • MES cannot communicate directly with the equipment.
  • Production records are entered at the end of each shift.
  • Downtime causes are incomplete.
  • Managers cannot see current output.
  • Manual entries may contain errors.

Proposed Architecture

  1. An industrial computer connects to the machines through RS-485.
  2. A local application reads machine status, alarms, and production counts.
  3. The software converts the data into a format accepted by MES.
  4. The industrial computer stores short-term data locally.
  5. Production records are sent to MES through Ethernet.
  6. If the network fails, the industrial computer continues collecting data.
  7. Stored records synchronize when the connection is restored.

Expected Operational Value

This type of industrial computer deployment can provide:
  • More timely production status
  • Reduced manual data entry
  • More complete downtime records
  • Better support for OEE analysis
  • Improved production traceability
  • Continued use of existing equipment
The actual result depends on the machine protocol, software integration, data quality, and project execution. Manufacturers should avoid promising a fixed efficiency percentage before testing the solution.

industrial-computers-for-digital-transformation-2


How Should Manufacturers Implement Industrial Computers in a Digital Transformation Project?

Step 1: Begin with a Business Problem

Do not begin by purchasing the most powerful industrial computer.
First define the operational problem:
  • Unplanned downtime
  • Incomplete production data
  • Slow quality inspection
  • Poor product traceability
  • Manual reporting
  • Legacy equipment isolation
  • High energy consumption
  • Limited remote support
A clear business goal makes it easier to define hardware and software requirements.

Step 2: Audit Existing Equipment

Document:
  • Machine model
  • Controller type
  • Available interfaces
  • Communication protocol
  • Existing software
  • Operating system
  • Network connection
  • Installation space
  • Power input
  • Environmental conditions
This audit prevents the project from selecting an industrial PC that lacks an essential interface or software driver.

Step 3: Define the Required Data

Collect data that supports a specific decision or Key Performance Indicator (KPI).
For example, an OEE project may need machine state, production count, cycle time, reject quantity, and downtime reason. It may not need every internal controller value.

Step 4: Start with a Pilot Project

Choose one machine or one production line.
A pilot should confirm:
  • Data can be read correctly.
  • Software is compatible.
  • Network communication is stable.
  • Local storage and recovery work correctly.
  • Operators can use the system.
  • The project creates measurable operational value.

Step 5: Select the Industrial Computer

Match the computer to:
  • Workload
  • Interface requirements
  • Software
  • Environment
  • Installation
  • Expansion
  • Product lifecycle
  • Project budget

Step 6: Integrate OT and IT Systems

Connect the industrial computer to the required PLCs, sensors, machines, databases, MES, SCADA, ERP, or cloud services.
Responsibilities between the automation, IT, software, and equipment teams should be clearly defined.

Step 7: Validate Reliability and Cybersecurity

Test:
  • Power-loss recovery
  • Network interruption
  • Data buffering
  • User permissions
  • Remote access control
  • Backup and restoration
  • Application restart
  • Operating temperature
  • Long-duration operation
The NIST Cybersecurity Framework 2.0 organizes cybersecurity risk management around Govern, Identify, Protect, Detect, Respond, and Recover. This provides a useful high-level framework for manufacturers connecting more production assets to digital networks.

Step 8: Measure Results and Scale

After the pilot, compare the results with the original baseline.
If the architecture works, standardize:
  • Hardware configuration
  • Operating system image
  • Software version
  • Interface mapping
  • Security settings
  • Data format
  • Installation method
  • Maintenance procedure
Standardization makes it easier to deploy industrial computers across more machines, production lines, and factories.


How Do You Choose an Industrial Computer for Digital Transformation?

Processing Performance

Ask what the industrial computer must run.
Data collection and protocol conversion may require less computing power than multi-camera machine vision, virtualized applications, or AI inference.

Memory and Storage

Consider:
  • Number of simultaneous applications
  • Local database size
  • Image and video storage
  • Data-retention period
  • RAID requirement
  • Operating system
  • Future software expansion

Interfaces

Confirm the exact number and type of:
  • Ethernet ports
  • 2.5GbE or Gigabit LAN
  • USB ports
  • RS-232 ports
  • RS-422/RS-485 ports
  • CAN
  • GPIO
  • HDMI, DisplayPort or VGA
  • PoE camera ports
  • Wireless connections

Expansion

Projects may require:
  • PCIe expansion
  • Motion-control cards
  • Data acquisition cards
  • Frame grabbers
  • PoE cards
  • GPU cards
  • AI accelerator cards
  • Additional network cards

Installation and Environment

Check:
  • Wall, rack, panel or DIN-rail installation
  • Available space
  • Dust level
  • Vibration
  • Temperature
  • Humidity
  • Power supply
  • Airflow
  • Service access

Software Compatibility

Confirm support for:
  • Windows or Linux
  • Existing HMI and SCADA applications
  • Machine vision software
  • Drivers
  • Databases
  • Virtualization
  • Remote-management tools
  • Custom applications

Product Lifecycle and Customization

A successful manufacturing deployment may remain in service for many years. Manufacturers should discuss platform availability, replacement planning, system images, BIOS requirements, interface customization, and technical support with the supplier.
industrial-computers-for-digital-transformation-1


SINSMART Industrial Computer Examples for Different Projects

The following models illustrate how different types of industrial computers can serve different digital transformation roles. Final configurations and availability should be confirmed for each project.
Model Main verified configuration Suitable project direction
SIN-3412-R680E

Supports Intel 12th/13th Gen Core i3/i5/i7/i9;

up to 128GB memory; two 2.5GbE ports plus one

Gigabit LAN; six USB 3.2 Gen 2 ports; two RS-232/422/485 ports

Multi-network edge processing,

data acquisition and expansion-heavy applications
SIN-156-1135

15.6-inch platform; Intel Core i5-1135G7; up to

 64GB DDR4; one 2.5GbE and one Gigabit LAN;

six USB ports; four serial ports in the listed configuration

HMI, production dashboards, machine control

and line-side data visualization
SIN-4100-ZQ370MAV2 4U

Supports Intel 8th/9th Gen Core i3/i5/i7;

up to 128GB DDR4; four SATA III ports; two

Gigabit LAN ports; 12 USB ports; six COM ports

Control rooms, centralized data acquisition

and projects requiring rack installation or expansion
The SIN-3412-R680E is suited to applications that require modern processors, several network connections, high-speed USB, and industrial serial communication.
The SIN-156-1135 combines computing and a touchscreen in one unit, making it more suitable for operator interaction, HMI software, process monitoring, and production dashboards.
The SIN-4100-ZQ370MAV2 uses a 4U rackmount format. This type of industrial computer is appropriate when a project requires internal expansion, centralized installation, several peripheral connections, or easier hardware maintenance.
Manufacturers can also explore SINSMART’s broader industrial PC product range, including embedded industrial computers, rackmount systems, industrial panel PCs, rugged tablets, rugged laptops, and portable industrial computers.


Where Are Industrial Computers Used Across Manufacturing Industries?

Industry Typical applications
Automotive Robot monitoring, machine vision, traceability and test systems
Electronics Automated Optical Inspection, defect detection and equipment monitoring
Food and beverage Production monitoring, recipe control and batch traceability
Pharmaceutical Batch records, equipment monitoring and production data collection
CNC machining Machine status, program management and MES connectivity
Packaging HMI, motion systems, barcode tracking and vision inspection
Warehousing AGV, AMR, RFID, inventory and fleet management
Machine building Embedded control, HMI and remote maintenance
Energy and utilities Condition monitoring, data logging and equipment control
Transportation equipment Testing, diagnostics and production traceability
For logistics-focused deployments, SINSMART has additional guides covering industrial PCs for smart warehouse automation and industrial PCs for AGV and AMR fleet management.
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How Can SINSMART Support Manufacturing Digital Transformation Projects?

SINSMART is the industrial computing brand of Hangzhou Dongtian Technology Co., Ltd. As a factory manufacturer rather than a trading company, we integrate product development, manufacturing, sales, and project support.

Broad Industrial Computer Portfolio

SINSMART provides:
  • Fanless embedded industrial computers
  • Industrial edge computers
  • Rackmount industrial PCs
  • Industrial panel PCs
  • Machine vision computers
  • GPU and AI computing systems
  • Rugged tablets
  • Rugged laptops
  • Portable industrial computers
This allows manufacturers, system integrators, and machine builders to select a hardware format that matches the installation instead of forcing one type of computer into every application.

Hardware and Interface Customization

Depending on the project and platform, SINSMART can evaluate requirements involving:
  • CPU, memory, and storage
  • COM, LAN, CAN, GPIO, and USB
  • PCIe expansion
  • GPU or AI acceleration
  • Installation structure
  • System images
  • BIOS settings
  • Enclosure and branding
  • Operating system
  • Project-specific I/O

OEM and ODM Support

SINSMART works with:
  • Manufacturing enterprises
  • Automation system integrators
  • Machine builders
  • Equipment manufacturers
  • Industrial software companies
  • Importers and distributors
For repeat or volume projects, our team can review the complete application rather than recommending hardware based only on a processor model.

Information to Provide When Requesting a Recommendation

To receive a more accurate industrial computer recommendation, provide:
  1. Application and software
  2. Required CPU, GPU, or AI performance
  3. Memory and storage
  4. Number and type of interfaces
  5. Expansion cards
  6. Operating system
  7. Installation method
  8. Power input
  9. Operating temperature and environment
  10. Estimated quantity
  11. Required certifications
  12. Customization needs
Planning a manufacturing digital transformation project?
Tell SINSMART what machines, software, interfaces, and operating conditions your project involves. Our team can help evaluate a suitable industrial computer platform or discuss an OEM/ODM configuration.


FAQ 

Q1：What is an industrial computer in manufacturing?


An industrial computer is a computing platform designed or configured for industrial applications such as machine control, production monitoring, data acquisition, machine vision, HMI, and edge processing. Depending on the model, it may provide industrial interfaces, expansion slots, specialized mounting, fanless cooling, DC power input, or wider environmental specifications.


Q2：How do industrial computers support digital transformation?


Industrial computers support digital transformation by collecting data from machines, processing it near the production line, running industrial applications, and transferring useful information to SCADA, MES, ERP, databases, or cloud platforms.


Q3：What is the difference between an industrial PC and a PLC?


A PLC is primarily designed for deterministic machine control and industrial I/O. An industrial PC offers general-purpose computing, storage, visualization, database, machine vision, and software capabilities. Many manufacturing systems use PLCs and industrial computers together rather than replacing one with the other.


Q4：Can industrial computers connect old machines to MES?


Yes, an industrial computer may connect legacy equipment to MES when compatible interfaces, protocols, drivers, and integration software are available. The machine must be audited before the hardware is selected.


Q5：Do manufacturers still need edge computers if they use the cloud?


Yes, when an application requires low latency, offline operation, local AI, reduced bandwidth, or control over sensitive production data. Edge and cloud systems normally perform different roles and can be used together.


Q6：What industrial computer is suitable for machine vision?


The correct system depends on camera quantity, interface, resolution, frame rate, inspection software, storage, and response time. Multi-camera or AI inspection may require additional LAN or PoE ports, PCIe expansion, high-speed storage, and GPU or AI acceleration.


Q7：Are fanless industrial computers always better?


No. Fanless systems are useful when dust, maintenance, and fan reliability are major concerns. High-performance processors or GPUs may require active cooling. The cooling design should match the workload and environment.


Q8：Can one industrial computer run several manufacturing applications?


It may be possible if the processor, memory, storage, operating system, and software licenses support the workload. Virtualization can also separate applications, but the complete configuration should be tested before deployment.


Q9：What information should a manufacturer provide when requesting a quotation?


Provide the application, software, CPU or GPU requirement, memory, storage, interfaces, expansion cards, operating system, installation, power input, environmental conditions, quantity, certification needs, and customization requirements.


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