HMI software

Human machine interface (HMI) software gives machine operators a way to interact with and manage a system. This interaction is through a graphical user interface (GUI), which facilitates information exchange and communication between two types of HMIs; a supervisory level and a machine level. Generally, HMI software is designed for either machine level HMI or supervisory level HMI, with applications suitable for both types. These software applications are expensive at the outset, but can lower long-term costs and reduce redundancies in the long run.

Selecting HMI software typically starts with an analysis of product specifications and features. The key considerations can include the system architecture, performance requirements, integration and cost of procurement and operations.

The HMI system typically presents the information to the operator through some sort of GUI. More advanced HMI systems allow operators to view diagrams, digital photos and detailed system schematics. For motion control applications, the visual GUI can range from simple 4 line x 20 column text displays to color monitors with touchscreen controls. HMI display screens come in standard, advanced, compact and high performance versions. The latter can be customized based on the operator’s requirements. The standard version is normally used on low-cost systems that are not task-intensive.

Sometimes, an HMI unit can be programmed to perform some basic control functions as well, such as editing servomotor parameters and even issuing global commands to other control axes on a machine. This places them well beyond a basic type of HMI with only simple functions such as observing processes or making very simple changes to some individual variables or parameters or setpoints.

HMI software editors are available to provide touch screen functionality through a multitude of dimensions and colors. Additionally, they offer control functions for industrial automation machines. Programming can be done using Windows-based and screen editor software. It can permit quick editing of schematics and set suitable communication protocols.

HMI accessories complement the displays based on the requirements of the operator. Depending on the complexity of the application, there are a range of I/O options available such as the number of digital or analog inputs or outputs, and communication protocols range from simple RS-232 links to more advanced protocols such as CANOpen, SERCOS, and Ethernet-based communications.

Communications on multiple networks are supported through ControlNet and DeviceNet. ControlNet is a control-level network that provides high-speed transmission of time-critical messaging data and I/O data. DeviceNet handles industrial devices like drives, limit switches, motor starters, operator displays, photoelectric cells, and valve manifolds to personal computers (PC) and programmable logic controllers (PLC). The use of both communication systems provides HMI software data management between the machines and operator interactions.

More sophisticated HMI software is structured around mobile, portable platforms such as the Microsoft Windows CE platform, a scalable version of the Windows operating system for handheld devices. This presents a cost-saving value as the operating systems are distributed on machine-level embedded HMI, solid-state open HMI machines, distributed HMI servers and portable HMI devices.

Rotary table wheel-blast system features a streamlined HMI

Guyson Corporation (www.guyson.com) has introduced a rotary table wheel-blast system with a streamlined human-machine interface (HMI) that effectively replaces a collection of separate switches, indicators and push buttons with a sleek panel that simplifies use of the controls, while allowing users to view the status of the system functions — the GWB-702T. Graphically representing touch-and-select control functions, the compact HMI offers text instructions or prompts related to fault indications and permits direct entry of process parameters, such as air wash blow-off cycle time or blast cycle time, to the programmable logic controller of the system.

The new rotary table wheel-blast system comes with one blast wheel over every half of a 70-inch diameter, 4,000 pound capacity turntable, making it ideally suited for batch processing of essentially flat work pieces or have limited vertical surfaces.

Heavily equipped with abrasion-resistant cast iron alloy plates, the table of the wheel blast machine also features protective armor of similar material hung on the blast chamber’s walls and interior ceiling to cover the all areas in line directly with the blast wheels.

It is also fitted with an optimized shot reclamation system that has an independent adjustable cyclone separator for capturing and reusing grit or good shot that could otherwise be carried over to the dust collector.

A media reclamation system helps the blast machine maintain negative pressure and balance the air flow. The wheel blast machine also features a freestanding Guyson Model D2000 cartridge-type dust collector that offers an extraction capacity of 2,000 cubic feet of air per minute.

Intel introduces multi-core technology that consolidates controls

The main attraction of an Intel multi-core processor is how an industrial automation vendor is allowed to create solutions using PC-based technology as well as other standards-based components, said Ian Gilvarry of Intel Corporation (www.intel.com).

“These solutions scale capacity and integrate special functionality more easily than platforms based on dedicated hardware,” said Gilvarry, who is the marketing manager at Embedded and Communications Group for Intel Corp.

Rather than installing a number of system boards for HMI and control functions, multi-core processors allow consolidation of applications onto one board, he said. This boosts processing flexibility and power and further improves control performance.

Intel’s Atom processor and integration with certain input and output interfaces are important to control usage, he added.

“Without a doubt, we will see more multi-core CPUs (central processing units) being used in the industrial and embedded spaces as multi-core technology trickles down into smaller and lower-power designs,” said Casey Weltzin, product manager of LabView Real-Time, with Texas-based test and automation supplier National Instruments Corp. (www.ni.com). “The Intel Atom processor is a very good example of this trend.”

Beckhoff Automation LLC (www.beckhoffautomation.com) is now working with Intel on the next-generation Atom. “It has a low-heat, low-power footprint,” said Corey McAtee, technical marketing manager at Beckhoff. He envisions a paperback-novel-size controller that features low power and heat doing complete machine control, from HMI to PLC control between motion and robotics.

Mr. Weltzin shares the same vision, adding: “Multi-core CPUs and the work being done by Intel are clearing the way for more complex algorithms to be used (e.g., machine control) that can improve the capabilities and efficiency of machines. Designers will be able to reduce power consumption and size of current applications that require a lot of computation.”

Intel’s goal is to attain a single architecture converged on an embedded PC. “In the next several years, we may see many-core CPUs with 16, 32 or more cores,” Weltzin said, adding that it will force programmers to be much more adept at parallel application development. “It will also push researchers and companies like Intel to invest in interconnect technology for networking the CPU cores on a chip,” said Gilvarry.

As the number of cores increases, real-time response is, however, getting shorter. McAtee said: “In an EtherCat network with distributed controllers, the ‘slave’ device becomes more like a microcomputer, capturing data at 10-20 microseconds, with 10-20 nanosecond jitter. With [our] TwinCat 3.0, which has two cores, I can say I want one core to handle one high-speed task, such as registration, at 50 microseconds. The next core would do the basic programmable logic state, which you could set at 10 seconds.”

Standalone EtherCAT Master Controller can handle complex machine control tasks

The new EtherCAT master controller can operate high-level machine control tasks like application systems, communication with the host HMI or PC, multi-axis motion profile generation, error and safety handling. The SPiiPlus NTM has the capability to control up to 32 axes in fully synchronized motion, while all time control tasks are handled by slave drives.

To provide additional I/O and drive capabilities, the SPiiPlus NTM controls ACS slave modules, such as MC4Udc (up to 8 axis drive chassis for stepper motors or servo motors), UDMnt (up to 2 axis drive module for stepper motors or servo motors), IOMnt (up to 32/32 digital I/O module), PDMnt (up to 4 axis Pulse or Direction Interface module), and SDMnt (up to 8 axis stepper drive module).

The SPiiPlus NTM controller has also the ability to control any third party I/O or EtherCAT drive modules, which are qualified by ACS Motion Control (www.acsmotioncontrol.com).

Supported by ACSPL+ motion programming language, the SPiiPlus NTM also features a set of software tools such as the SPiiPlus’ MMI Application Studio and API for host application development. The tools comprise a full PC-based controller simulator that reduces the cost of ownership, as well as time-to-market for system integrators, end users and OEMs.

“The SPiiPlus EtherCAT family of products offer advanced, high-level machine control with a smaller footprint and smaller cost when compared to competing control solutions,” said Jason Goerges, ACS Motion Control‘s sales and support manager. “Our universal drive technology provides a flexible solution for all motor topologies, further helping to reduce costs, as users can run several axes from one drive module.”

Cognex’s embedded vision systems support PLCs and HMIs

Cognex (www.cognex.com) is making a breakthrough in embedded vision systems that support programmable logic controllers (PLC) and human-machine interface (HMI) industrial protocols.

Nowadays, if the manufacturing system of the customer has a Rockwell PLC, then the vision system must talk to it, said Rick Roszkowski, the company’s senior director of vision systems marketing, adding that this ability to communicate is becoming a customer expectation.

“To meet it, we’re building tools within the smart camera, as well as including the ActiveX control software component for integration into third-party HMI systems,” said Roszkowski. “The demand for extending software features and tools to help quickly integrate vision into the industrial environment is becoming as important as the demand for new vision tools to solve a particular application. Most companies don’t have the time, and often not the expertise, to create a program that makes all those devices exchange data easily and quickly.”

Samantha Frost, product marketing specialist at Cognex, said OEMs look first for the ease of development and then integrate vision into other factory systems. “This means connecting to major factory communication protocols such as PROFINET, EtherNet/IP, and Modbus TCP, as well as interfacing with HMI programs,” said Frost.

Looking ahead, the company plans to give more pixels and more horsepower to its vision system products so they can handle data more accurately. “We want to make smart cameras and vision systems smarter, and make them play well with the rest of the factory,” she said. “So, we expect to provide more powerful application-building tools that require little or no operator input to set up the machine to accomplish the vision task.”

Kamalina Srikant, vision product manager at National Instruments, said embedded vision systems are utilized in scientific contexts including failure analysis labs and R&D, and industrial applications. The application’s complexity in industrial environments does not come from image-processing requirements but from the synchronization and the need to integrate vision system with other industrial systems such as control systems, robots, and PLCs, to handle the inspection results. Customers want a wider range of industrial communications options. “For example, you might need to ensure that your vision system uses a certain protocol to talk to one of the more expensive industrial robots on your line,” said Srikant. New Embedded Vision System models from NI are the first vision systems to support Ethernet for Control Automation Technology or Ethernet-based fieldbus system EtherCAT, also called deterministic Ethernet.

Advantech introduces new HMI Line for PLC Control

Advantech Automation Corp. (www.advantech.com/ea) is proud to announce the release of the WOP-2000 series for applications that involve the use of motion/thermal controllers, PLCs, sensors and inverters. The new series is bundled with a PM Designer 2.0 – a software development kit which creates application solutions for easy control of machines within the factory, labor-saving and improved efficiency of manufacturing. The WOP-2000 series provides a great price performance ratio for several markets, including HMI + communication gateways, conventional operator panels and HMI + low mini SCADA systems.

The easy-to-use PM Designer features high-end vector graphics, solution-oriented screen objects, Microsoft Windows(TM) fonts for multi-language applications, operation logging, data loggers, alarms and recipes. The integrated development tool also includes online/offline simulation and other utility programs like Data Transfer Helper (DTH); text editors and recipes editors. The series’ runtime, which is part of PM Designer, guarantees performance and reliability because of high communication data rates, sub-second screen switching, minimum system overhead and 24/7 operation.

The new series consists of up to 200MHz ARM9-based processors and 4 to 16MB flash memory. It can support several LCD sizes from 3.5 inches to 12.1 inches and is best suited for applications that involve the use of motion/thermal controllers, PLCs, inverters and sensors.

With a variety of communication interfaces such as RS-232/422/485 Ethernet and USB ports, the series can be easily connected to several equipments. Its monitors boast SVGA TFT LCDs with 800×600 resolution and 64K colors for clear displays in any factory setting. Moreover, the product includes 0 to 50° C operating temperatures and NEMA 4/IP65 protection to guarantee performance in hash environments.

The series is compatible with more than 250 of the most popular PLCs, such as Modicon Quantum™ series, Allen Bradley Micrologix series, Siemens AG Simatic S7 series, GE series 90™, Omron Corporation Sysmac C/CV/CS/CJ series, Yaskawa Corp. MP series and Mitsubishi Electric Corp. FX/Q series.

Beijer Electronics Launches HMI I/O Controller

Developed by Beijer Electronics, this new I/O module enables easy interfacing with Beijer Electronics’ HMI and allows the user to implement simple monitoring and automation tasks without the need of a PLC. The HMI I/O Controller is an easy-to-install and cost effective solution.

The compact new HMI I/O Controller is specially developed for the plus version of the H-T40, the H-T40m-P, which features extended memory. The module facilitates the aim of the H-series to offer valuable HMI functionality at the precise level required by the customer.

Up to 16 modules per H-T40m-P can be stacked up and the module’s built-in processor means that the H-T40m-P operates at optimal speed with no adverse effects.

This compact I/O module can be easily mounted on the back of the H-T40m-P. The HMI I/O Controller features 12 Digital inputs / 4 Digital outputs. Other versions, including analog I/O modules, are in the pipeline. Up to 16 modules per H-T40m-P can be stacked up and the module’s built-in processor means that the H-T40m-P operates at optimal speed with no adverse effects.

Beijer Electronics’ products manager Troy Lin explains, “The HMI I/O Controller is the first I/O module to be developed by Beijer Electronics. It is a perfect solution, affording a direct interface with our H-T40m-P that is compact, cost-effective and easy to install”.

Monitoring and automation tasks can easily be developed with the H-T40m-P’s software, H-Designer. This intuitive HMI configuration software features flexible tools that allow projects to be created in just a few minutes and offers instant off-line and on-line simulation. H-Designer saves valuable time, providing ready-made modules that can be utilized for arithmetic calculations, logical operators and bit settings etc.

The HMI I/O Controller is perfect for utilization within a varied range of industries. Among other things, the module may be used for controlling on/off switches for light output in Building Automation or for pump control throughout the Water & Irrigation industry and agriculture facilities.

www.beijerelectronics.com