COM-HPC Mini High-Performance Computer-On-Module for Railway PCs

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Embedded computers for the railway industry must withstand strong vibrations, temperature fluctuations, and electrical interference. A challenge for developers.

The starting point for developing Syslogic's RML-R10 railway computer was a clear market demand: a compact and powerful embedded system for the transportation sector. The railway computer was primarily designed as an onboard computer—usable as a rail control unit, collision warning system, as well as for predictive maintenance or ADAS (Advanced Driver Assistance Systems). Additionally, the computer is suitable for off-train applications such as track monitoring or track vacancy detection.

From Customer Needs to A Comprehensive Solution

Many railway applications also require that embedded systems be housed directly in the driver's cab or in switch cabinets—every inch of space counts. At the same time, the demands for computing power, connectivity, and future-proofing in the railway sector continue to rise.

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The core of the computer is a COM-HPC Mini module from Congatec, which, thanks to its high performance, compact form factor, robust design, and interface versatility, is ideally suited for railway applications. By combining a custom-developed Syslogic carrier board, a robust housing, industrial-grade interfaces, and the powerful Congatec module, a complete system was created that fully meets customer expectations. European rail vehicle manufacturers, railway operators, and system integrators are already successfully using the RML-R10 in various projects and applications in the transportation sector.

COMs vs. Full-Custom Designs

A computer-on-module (COM) combines the essential components of a PC on a compact board, including the CPU, memory, and basic I/Os. Unlike single-board computers (SBCs) or motherboards, however, the COM does not function on its own but is installed on a carrier board—also referred to as a carrier.

The major advantages of COMs compared to standalone solutions or full-custom designs include scalable performance through processor upgrades, a selection of various form factors for different requirements, and easy upgrades via module replacement instead of a redesign. Additionally, standardized COMs are available from multiple manufacturers and thus reliably available over the long term. This ensures future-proof connectivity. Separating PC development from the actual application development also reduces time-to-market. At the same time, the reusability of the carrier board lowers NRE costs.

When it comes to computer-on-modules, the widely and successfully used COM Express standard, which is also available in a mini format, is the first to come to mind. However, since October 2023, there is an alternative: COM-HPC Mini.

COM-HPC Mini from Congatec As A Basis

With its standardized dimensions of 3.7 in × 2.8 in, the Computer-on-Module conga-HPC/mRLP from Congatec is extremely compact and ideally suited for tight installation spaces. Additionally, it features state-of-the-art high-speed interfaces such as PCIe Gen4, USB 4.0, and fast Ethernet standards, providing a high level of future-proofing. Crucial for Syslogic was also the fact that the CPU and RAM are soldered, which positively impacts vibration resistance in railway operations.

The conga-HPC/mRLP module also integrates the powerful 13th generation Intel Core processors (Raptor Lake). Combined with "on-module" DDR5 memory technology, it creates a performance package that is excellently equipped for complex applications such as video analysis or control logic.

The combination of Syslogic's application-specific carrier board with a COM-HPC Mini module from Congatec offers high flexibility for customer-specific requirements as well as excellent scalability and modularity. Syslogic can upgrade to the latest processor generation (SKUs) whenever necessary. Additionally, replacing the module is straightforward. A redesign of the hardware or cooling system is not required. The carrier board remains unchanged, with only a more powerful module being installed. This allows new customer requirements to be implemented flexibly and quickly—an investment that pays off.

Certified Railway Suitability

Not only must the COM be designed to meet the high demands of railway technology, but the rest of the peripherals of the railway computer must also comply with the strict requirements of embedded designs. For 25 years, Syslogic has been supplying the railway industry and consistently meets the high standards and harsh environmental conditions of the sector with its products. Even during component selection, Syslogic ensures that only parts compatible with railway requirements are used. As a result, the Railway Computer RML-R10 meets requirements for:

• EN 50155, Class OT4: Operation in an extended temperature range from –40 to 185 °F
• EN 50125: Environmental conditions for railway equipment such as temperature, humidity, mechanical influences, rain, snow, hail, ice, or solar radiation
• EN 45545-2 HL3: Fire protection requirements for equipment
• EN 61373: Requirements for shock and vibration resistance

For instance, the computer withstands power outages with a 10-ms bridging time (EN 50155 Class S2) and can be operated on all common onboard networks with a galvanically isolated wide-range input (16.8 to 137.5 V_DC) without the need for additional DC/DC converters. Contributing to its robustness are screw-lockable M12 connectors, a passive cooling concept, and a solid housing design. Additionally, every device undergoes extreme testing before delivery, including cold-start tests at sub-zero temperatures.

This robustness extends modularly to the COM-HPC Mini module. It largely relies on soldered connections (no plug-in RAM) for high shock and vibration resistance. Furthermore, it is also capable of withstanding harsh industrial applications, such as temperatures ranging from –40 to 185 °F, and is based on a sturdy PCB design.

Due to its modularity, Syslogic can specifically add additional features such as extra insulation, galvanic isolation, or optimized EMC compatibility depending on the application area, without needing to modify the core computing module.

Connectivity for Future-Proof Designs

To ensure the future-proofing of its railway technology applications, Syslogic relies on custom interface layouts that can be configured as IP-protected interfaces depending on the requirements. Standard interfaces include Ethernet (M12, screw-lockable), CAN, RS232/422/485, and digital I/Os. Optionally, features such as Power-over-Ethernet (PoE), Single Pair Ethernet (SPE), additional LAN or CAN ports, and DisplayPort can be integrated. Since USB is not a commonly used standard in railway technology, it is installed exclusively for maintenance purposes.

To ensure the future-proofing of its railway technology applications, Syslogic places great emphasis on custom interface layouts, which can be configured as IP-protected interfaces depending on the requirements. Standard interfaces include Ethernet (M12, screw-lockable), CAN, RS232/422/485, and digital I/Os. Optional features such as Power-over-Ethernet (PoE), Single Pair Ethernet (SPE), additional LAN or CAN ports, and DisplayPort can also be added. Since USB is not a widely used standard in railway technology, it is installed exclusively for maintenance purposes.

Virtualization And Security

With modern Intel processors and virtualization technologies such as Intel's VT-X and VT-D, the railway computer supports hypervisors like congatec aReady. This enables the consolidation of multiple functions on a single hardware platform that previously operated separately, such as:

• Video surveillance
• Passenger information
• Predictive maintenance
• Train control

Using virtualization, these applications run isolated and in parallel on the same system. This saves space, reduces costs, and increases efficiency in the vehicle. With the Railway Computer RML-R10-SPE, Syslogic is also introducing Single-Pair Ethernet to the railway industry for the first time. Each SPE interface is equipped with its own dedicated Network Interface Controller (NIC), enabling real-time communication with cameras and other sensors.

For railway operators, however, not only performance but also a high level of IT security and maintainability is crucial. For this reason, Syslogic integrates various security mechanisms into its railway computer, including TPM 2.0, UEFI Secure Boot, Intel's Control-Flow Enforcement (CET), and Intel's Total Memory Encryption. With these features, Syslogic achieves high data integrity while protecting the system from external attacks.

Beyond the railway sector, the new platform is also suitable for buses, trams, construction machinery, off-highway vehicles, and agricultural technology. Syslogic also plans further variants that will support AI workloads based on Intel. (mk)

Claire Liu is Senior Market Segment Manager at Congatec.

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