Legacy systems are still the backbone of many manufacturing operations, especially when specialized machines like custom rip saws are involved. But what happens when those systems depend on outdated operating systems like Windows XP and obsolete hardware?
In late 2023, a wood manufacturing company faced exactly that problem—and turned to SmallPC for help. Their rip saw, used for producing high-end wood frames, relied on custom software that only ran on a Windows XP-based PC. When the original machine failed, the company needed a rugged, dustproof industrial computer that could run legacy software and support a full-size Opto22 PCI I/O card.
⚙️ The Legacy Hardware Challenge: Modern Support for Obsolete Systems
Supporting legacy applications like this is a growing challenge in industries that depend on custom-built machinery. New PCs no longer support Windows XP, and older PCI cards often don’t fit into today’s compact hardware designs. This creates serious risks for production downtime and business continuity.
🔧 The Solution: SC240ML Industrial Computer from SmallPC
To meet this complex challenge, SmallPC recommended the SC240ML, a rugged industrial PC designed for tough environments and flexible hardware configurations. Here’s how it solved the problem:
✅ 1. Full-Size PCI Card Support
Unlike most modern systems, the SC240ML supports full-length PCI expansion cards, making it ideal for integrating legacy interfaces like the Opto22 card. Engineers at SmallPC repurposed internal space typically used for drive bays to accommodate the large PCI card securely.
✅ 2. Dustproof Industrial Enclosure
The woodworking environment posed another risk: sawdust. SmallPC’s SC240ML features a fully sealed, fanless chassis designed to block out fine particles, ensuring uninterrupted performance even in harsh shop conditions.
✅ 3. Native Windows XP Compatibility
SmallPC collaborated with the customer’s original software developer to identify a motherboard that could support Windows XP and legacy drivers. The operating system was installed and tested with full support for the Opto22 card and the saw’s custom software, ensuring seamless functionality.
✅ 4. Custom Software Compilation & Support
To ensure smooth operation, SmallPC worked closely with the customer’s development team to compile the original software directly on the new PC, delivering a fully functional plug-and-play solution. The result? Minimal downtime and a long-term fix.
Why Legacy Hardware Still Matters
This situation isn’t unique. Countless manufacturers, utilities, and industrial companies rely on aging control systems and custom applications that were never designed for modern operating systems. Replacing these systems entirely is often costly—or impossible due to proprietary software or specialized hardware dependencies.
SmallPC’s experience in custom industrial PC design makes it the go-to partner for legacy support, especially when ruggedization and environmental resilience are required.
Why the SC240ML Stands Out in Industrial Applications
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Compatible with legacy OS like Windows XP and 7
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Rugged aluminum enclosure — dustproof and fanless
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Supports full-size PCI expansion cards
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Ideal for factory floors, machine shops, and harsh environments
Whether you’re dealing with legacy software, unique I/O requirements, or environmental hazards like dust and moisture, SmallPC delivers industrial-grade solutions that last.
Need a Custom Rugged PC to Support Legacy Systems?
If your operations rely on legacy software or outdated control hardware, SmallPC can help. We design custom industrial computers tailored to your environment and technical requirements—ensuring reliability, compatibility, and performance.
Talk to us today to learn how we can help extend the life of your legacy systems with modern, rugged computing solutions.