Zachary Amos, Editor of ReHack Magazine, shares the design strategies to keep in mind as climate change driven weather environments present challenges
Since rugged IoT devices are routinely deployed in remote areas and industrial environments, they must withstand harsh environmental conditions. A resilience-by-design approach is essential for mitigating the effects of physical impact, debris intrusion, shock, vibration and extreme temperatures.
Considerations for IoT design in extreme environments
Original equipment manufacturers (OEMs) should keep these key considerations in mind when designing IoT devices for harsh environments:
Extreme temperatures
The United Kingdom is not known for heat waves, but IoT devices don’t have to be deployed in deserts or tropical grasslands to overheat. Fluctuations can be damaging even if the temperature isn’t extreme. Temperature-tolerant device housing leverages effective heat dissipation or thermal insulation to protect sensitive internal components.
Batteries must perform well whether they are freezing cold or scorching hot. Lithium thionyl chloride batteries have exceptional thermal insulation, with a temperature ranging from -80 degrees Celsius to 125 degrees Celsius. As a bonus, their low self-discharge rate of 1% per year extends their operating lives to 40 years.
Precipitation and ice formation
Ice formation can increase the voltage standing wave ratio, potentially detuning antennas. Signal quality and power transfer efficiency can degrade, impacting rugged IoT device performance. The buildup increases the wind load, increasing the likelihood of equipment misalignment or damage. Precipitation poses similar problems.
Freeze-thaw cycles are particularly destructive because they force materials to expand and contract. Seal degradation and electronic component drift are likely outcomes. Insulators, waterproofing and cable glands are essential design features.
Intrusion and corrosion
Strategic enclosure design is crucial because it determines how resistant sensitive internal electronics are to dust, water, ultraviolet light and debris. Generally, silicone gaskets, waterproof adhesives and overlapping walls are good starting points. For select applications, antifouling or anticorrosion coatings may be necessary.
The Ingress Protection (IP) standard provides an excellent baseline. It defines how resistant a device is to solids and liquids, with zero representing no protection. An IP44 rating denotes 12 times more intrusion resilience than an IP22 rating. Complete protection means devices can withstand microscopic particles and continuous submersion in water.
The evolution of rugged IoT design strategies in the UK
Climate change impacts the frequency of extreme weather events and temperature patterns in the UK, influencing rugged IoT design standards. The number of days above 25 degrees Celsius could increase four times if the global temperature increases by 4 degrees Celsius. A two-degree increase would double the number of extremely hot days.
The frequency of sub-zero temperatures will decline. However, even though rugged IoT devices will face fewer freeze-thaw cycles, the UK will see more high-impact rainfall because of climate change. Prolonged rainfall could submerge areas not historically prone to flooding.
OEMs must consider these changes when designing new models. Electronics and battery technology advancements are lengthening life spans, so devices could soon be deployed in the field for half a century or more. Future-proofing will help ensure they reach their expected service life.
It is necessary to prioritise durability in the face of increasingly harsh conditions. However, manufacturers must also consider size, efficiency and connectivity. New regulations may force them to leverage renewable energy harvesting or secure long-range communications more effectively. However, consumers will still expect small form factors and user-friendly designs.
Building reliable IoT for challenging environments
Design standards will shift as industrial applications evolve, electrification advances and the climate changes. Forward-thinking manufacturers should consider how these influences will shape tomorrow’s best practises.
Exploring innovative solutions and adopting novel techniques early on could give OEMs a competitive advantage. At the very least, it could help them stay ahead of evolving regulations, preventing last-minute prototyping in the future.
Zac Amos is a freelance tech writer who specialises in IoT, cybersecurity, and automation. He is also the Features Editor at ReHack Magazine. Follow him on LinkedIn.
There’s plenty of other editorial on our sister site, Electronic Specifier! Or you can always join in the conversation by visiting our LinkedIn page.
