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Industrial Computer IPC backup and restore by software

Industrial Computer IPC backup and restore by software

Backup and restoring an Industrial PC (IPC) using software is system reliability and disaster recovery. The is best practices, methods, and software options for backing up and restoring IPCs. Captures the entire IPC system, including the OS, drivers, applications, and configurations.

Industrial Computer IPC backup and restore by software
Industrial Computer IPC backup and restore by software

1. Why Backup & Restore an Industrial IPC?

  • Prevent downtime in case of system failure
  • Recover from software corruption or malware
  • Ensure quick deployment of identical configurations across multiple IPCs
  • Protect important industrial process data

2. Backup Methods for IPCs

A. Full Disk Imaging (Recommended)

  • The Industrial PC system, including the OS, drivers, applications, and configurations.
  • Ideal for quick restoration after system crashes.

B. Software Options:

  • Acronis Cyber Protect (formerly Acronis True Image)
  • Macrium Reflect Backup systems
  • EaseUS Todo Backup Software
  • Clonezilla (Open-source)
  • Norton Ghost (Legacy)
  • Windows Backup & Restore
  • SyncBack
  • rsync (Linux-based)

C. File-Based Backup

  • Only backs up critical files and system configurations.
  • Useful for retaining logs, application settings, and user data.

D. Cloud-Based Backup

  • Stores IPC images or critical files in a cloud storage system.
  • Useful for remote access and disaster recovery.
SIMATIC IPC427D INDUSTRIAL PANEL PC 6AG4140-6BC25-0KA0 FOR BOBST PRINTING MACHINE
SIMATIC IPC427D INDUSTRIAL PANEL PC 6AG4140-6BC25-0KA0 FOR BOBST PRINTING MACHINE

3. How to Perform a Backup

A. Full System Backup (Image Backup)

  • Install the Backup Software on the IPC or a bootable USB.
  • Create a Bootable USB/CD (for bare-metal recovery).
  • Select “Create Full System Image” in the software.
  • Choose Backup Destination (External HDD, Network Drive, or Cloud).
  • Start Backup Process and verify backup integrity.
  • Schedule Automatic Backups for regular updates.

B. File-Based Backup

  • Select Important Files/Folders (e.g., PLC configurations, logs, software settings).
  • Choose Backup Destination (NAS, external drive, or cloud).
  • Enable Incremental Backup (to save changes only).
  • Set Up Automatic Backup Schedule.

4. How to Restore an IPC

BECKHOFF C6350-1016-0040 FOR HUSKY MACHINE IPC HPN 5271224
BECKHOFF C6350-1016-0040 FOR HUSKY MACHINE IPC HPN 5271224

A. Restore Full System Image

  • Boot from Rescue Media (USB/CD) created during backup.
  • Select “Restore System Image” in the software.
  • Choose Backup Image Location.
  • Start Restoration Process and wait for completion.
  • Reboot IPC and check for errors.

B. Restore Specific Files

  • Open the backup software.
  • Navigate to the backup storage.
  • Select the required files.
  • Restore files to the original or a new location.

5. Best Practices

  • Use Redundant Backup Solutions (Disk + Cloud).
  • Keep a Bootable Recovery USB Drive Ready.
  • Schedule Regular Automatic Backups (Daily/Weekly).
  • Test Restorations on a Spare IPC to verify backups.
  • Store Backups Off-Site to protect against physical damage.

6. Backing Up and Restoring an Industrial PC (IPC)

  • In case of hardware failure (hard drive crash, motherboard failure), software corruption (virus, malware), or accidental data deletion, a backup allows you to quickly restore the IPC to its previous working state, minimizing downtime.
  • Backups provide a safe point to revert to if a system upgrade or software update causes unexpected issues.
  • Backups can be used to quickly and consistently deploy software and configurations to multiple IPCs.
B&R-IPC-HMI for machinery
B&R-IPC-HMI for machinery

7. Backup Methods:

  • Image-Based Backups:
    • Create an image of the entire hard drive: This captures the operating system, applications, configurations, and all data.
    • Tools: Use specialized imaging software (e.g., Acronis True Image, Macrium Reflect) or built-in tools (if available) to create an image of the hard drive.
    • Storage: Store the image on an external hard drive, network drive, or cloud storage.
  • File-Level Backups:
    • Back up specific files and folders: This might include configuration files, application data, and user documents.
    • Tools: Use built-in Windows tools like File History or third-party backup software.
  • Image-Based Restore:
    • Restore the entire hard drive image: This typically involves booting from a recovery media (e.g., USB drive) and restoring the image to the hard drive.
  • File-Level Restore:
    • Restore individual files or folders: Copy the backed-up files and folders back to their original locations on the IPC.

8. Software Considerations:

  • Backup software: Select software that is compatible with your IPC’s operating system and meets your specific backup and recovery needs.
  • Application: Choose a backup method that minimizes downtime and ensures a quick and efficient recovery process.
CPC2800 Lenze cabinet PC for Zimmer Printing Machine in Bangladesh
CPC2800 Lenze cabinet PC for Zimmer Printing Machine

Summery

  • The specific backup and restore procedures may vary depending on the IPC model, operating system, and the chosen backup software.
  • Refer to the IPC manufacturer’s documentation for specific instructions and recommendations. By following these guidelines, you can ensure that your industrial PCs are properly backed up and protected against data loss.