In-depth Analysis of Industrial PC Interface Types: Selection Strategies for USB/HDMI/VGA/DVI and the Practical Value of USR-EG628
In the wave of Industry 4.0, the interface configuration of industrial PC has become a core factor influencing system stability, scalability, and operational efficiency. From ensuring device compatibility in old production lines to enabling multi-screen collaboration in high-end manufacturing, and from meeting real-time data acquisition requirements to addressing the computational power needs of edge computing, interface selection directly determines the technological ceiling of industrial systems. This article provides an in-depth analysis of the selection logic for four mainstream interfaces—USB, HDMI, VGA, and DVI—from three dimensions: technical characteristics, scenario adaptability, and cost-effectiveness. It also combines practical cases of the USR-EG628 industrial IoT controller to offer enterprises actionable interface configuration solutions.
As an analog signal interface introduced in 1987, VGA (Video Graphics Array) features a 15-pin trapezoidal structure that transmits images through red, green, and blue primary color analog signals. Its core advantage lies in its exceptional compatibility: In a textile machinery factory in Suzhou, a twisting machine produced in 1998 still relies on a VGA interface to transmit custom serial protocol data. Through the protocol parsing function of the USR-EG628, the original analog signal is converted into the Modbus TCP format, increasing equipment utilization from 68% to 92%. However, VGA also has significant limitations:
Image Quality Degradation: At 1080P resolution, long-distance transmission (>10 meters) is prone to ghosting. An actual test in an automobile factory showed a 37% increase in image blurriness at 15 meters of transmission.
Limited Functionality: Supports only video transmission and cannot carry audio or network signals, requiring additional wiring.
Technological Obsolescence: The proportion of VGA interfaces in the global industrial display market has dropped from 42% in 2020 to 12% in 2025, with mainstream manufacturers gradually phasing out this interface.
Applicable Scenarios: Old equipment retrofitting, low-cost temporary deployments, and monitoring scenarios with low image quality requirements.
DVI (Digital Visual Interface), introduced in 1999, eliminates analog conversion losses by transmitting digital signals and supports resolutions up to 2560×1600. In a smart factory in Chongqing, the USR-EG628 connects to a Mitsubishi FX5U PLC via a DVI interface, achieving 100ms-level data acquisition under the Modbus TCP protocol, with a response speed five times faster than that of a VGA interface. However, DVI's drawbacks limit its application scope:
Anti-Interference Bottleneck: Although it uses digital signals, single-link DVI has a bandwidth of only 4.95Gbps, supporting only a 30Hz refresh rate at 4K resolution.
Fragmented Functionality: DVI-D supports only video, while DVI-I can be compatible with VGA but requires an adapter, increasing system complexity.
Shrinking Ecosystem: In 2025, only 18% of new industrial PCs worldwide will still be equipped with DVI interfaces, gradually being replaced by HDMI/DP.
Applicable Scenarios: Industrial control with image quality requirements but no need for 4K, medical imaging equipment, and security monitoring systems.
HDMI (High Definition Multimedia Interface) has become the mainstream choice for industrial displays due to its integrated audio and video transmission and high bandwidth. Its core features include:
Resolution Support: The HDMI 2.1 standard supports 8K@60Hz or 4K@120Hz, meeting the needs of high-precision scenarios such as industrial design and digital twins.
Protocol Integration: Supports functions such as HDR, 3D, and ARC (Audio Return Channel). A semiconductor factory achieves 99.9% consistency in multi-screen display through automatic EDID (Extended Display Identification Data) negotiation via an HDMI interface.
Widespread Ecosystem: In 2025, 83% of global industrial displays will be equipped with HDMI interfaces, and mainstream industrial computers will provide at least two HDMI outputs.
Typical Case: In a smart park in Hangzhou, the USR-EG628 connects to a 4K display via an HDMI interface, displaying real-time equipment operation data, energy consumption curves, and warning information. Coupled with the WukongEdge edge platform, it achieves millisecond-level response, improving operational efficiency by 40%.
Applicable Scenarios: High-definition video surveillance, human-machine interaction interfaces, multi-screen collaborative workstations, and remote conference systems.
The USB (Universal Serial Bus) interface plays a triple role in industrial scenarios: data transmission, device power supply, and peripheral expansion. Its technological evolution path is clear:
Speed Leap: From 480Mbps in USB 2.0 to 40Gbps in USB 4.0, meeting the needs of high-speed devices such as industrial cameras and robotic arms.
Power Supply Capability: The USB PD 3.1 standard supports 240W power supply, directly powering industrial tablets and sensors, reducing wiring costs.
Protocol Expansion: Through USB-to-Serial chips, RS485/232 protocol conversion is achieved. A water group utilized the USB interface of the USR-EG628 to complete the data point configuration of 56 Modbus RTU water meters within 2 hours.
Key Data: In an industrial scenario with 200 devices, production lines using USB 3.0 interfaces saw a 22% increase in equipment utilization compared to those using USB 2.0, saving over 150,000 yuan in annual wiring costs.
Applicable Scenarios: Touch screen control, data acquisition terminals, mobile storage devices, and device firmware upgrades.
Pain Point: A blast furnace monitoring system in a steel plant includes 200 temperature sensors using a custom serial protocol (baud rate 9600, 8N1 format), with the original control cabinet supporting only VGA output.
Solution:
Deploy the USR-EG628 industrial IoT controller and connect to the sensors via its RS485 interface.
Use the custom protocol parsing function to map the original data into the Modbus TCP format.
Connect to the original display via the VGA interface and synchronously output monitoring images.
Upload data to the USR Cloud platform via 4G network for remote management.
Pain Point: A 3C manufacturing plant needs to simultaneously operate injection molding machines produced 20 years ago, imported Japanese robotic arms, and domestic AGV carts, requiring 4K display, multi-screen collaboration, and real-time data acquisition.
Solution:
The USR-EG628 connects to a 4K display via an HDMI interface to display the production line's digital twin model.
The USB interface connects to the robotic arm control handle, achieving millisecond-level command response.
The RS485 interface connects to the injection molding machine, enabling parameter downloading through protocol conversion.
The 4G module uploads AGV position data to the MES system to optimize scheduling logic.
Effect: The production line changeover time was shortened from 45 minutes to 12 minutes, and the yield rate increased by 3 percentage points.
Pain Point: A 220kV substation needs to achieve interoperability between the IEC 61850 and Modbus TCP protocols while monitoring 2,000 data points, requiring a transmission delay of <50ms.
Solution:
The USR-EG628 connects to a large-screen display via a DVI interface to display the SCADA system interface.
The USB interface connects to a dongle to ensure data transmission security.
The Gigabit Ethernet interface parses IEC 61850 messages and converts them into the Modbus TCP format.
The local configuration function sets alarm thresholds, automatically triggering emergency plans in case of abnormalities.
Effect: The fault location time was shortened from 15 minutes to 2 minutes, reducing annual power outage losses by over 3 million yuan.
As a new-generation industrial IoT controller, the USR-EG628 redefines the interface standards of industrial PCs through modular design and comprehensive interface coverage:
Interface Matrix: Standard configurations include RS485/232, CAN, LAN, USB, HDMI, and SIM card slots, supporting DP/DVI expansion.
Protocol Compatibility: Built-in with over 200 industrial protocol libraries, it can simultaneously handle heterogeneous protocols such as Modbus RTU, Profinet, and MQTT.
Edge Intelligence: With 1 TOPS computational power, it supports local AI inference, enabling edge computing tasks such as vibration analysis and energy consumption prediction.
Security Protection: Three-level surge protection, three-level electrostatic protection, and a system watchdog mechanism ensure stable operation under complex working conditions.
Typical Applications:
Smart Agriculture: Connect soil sensors via the USB interface, display temperature and humidity curves on an HDMI-connected display, and upload data to the cloud via the 4G module.
Industrial Manufacturing: Control PLCs via the RS485 interface, connect to HMIs via HDMI, update firmware via USB, and achieve full lifecycle management of production lines.
Building Energy Efficiency: Connect to air conditioning systems via the CAN interface, display energy consumption dashboards via HDMI, and optimize equipment operation strategies through the USR Cloud platform.
Needs Assessment: Fill out the "Industrial Interface Needs Diagnostic Form" to clarify key parameters such as application scenarios (e.g., production line control/environmental monitoring), load types (continuous/intermittent), and environmental conditions (temperature/humidity/dust).
Current Situation Analysis: Collect real-time device data using a power consumption tester to generate an "Interface Compatibility Report" and identify potential bottlenecks (e.g., VGA image quality loss, DVI bandwidth insufficiency).
Solution Customization: Match devices such as the USR-EG628 based on the diagnostic results and design a modular expansion solution (e.g., adding DP interface cards, USB Hubs).
Effect Verification: Deploy a pilot project, monitor interface utilization, transmission delay, and other indicators in real-time through the USR Cloud platform, and generate an "ROI Analysis Report."
Scan the QR code below, submit basic information such as device models and application scenarios, and you will receive:
Visit our official website, fill out the needs form, and our technical experts will contact you within 24 working hours.
Sample Testing Service: Submit your application requirements to obtain the opportunity to test samples and verify device performance in real environments.
Information Package: Includes the "Industrial Interface Selection White Paper" and the "USR-EG628 Test Report."
In the era of industrial IoT, interfaces have evolved from simple physical connections to "highways" for data flow. From VGA's persistence in compatibility to HDMI's breakthrough in high-definition, from USB's universal expansion to USR-EG628's protocol fusion, each interface iteration drives industrial systems toward greater efficiency and intelligence. Choosing the right interface configuration is not just a technical decision but also a strategic investment in an enterprise's digital transformation. Take immediate action and let every cable become a key link in unleashing productivity!
