Human-machine interfaces (HMIs): Hardware, software, and new modes of connectivity

Gone are the days of HMIs merely consolidating switches, pushbuttons, meters, and operator warning lights. Today’s HMIs now control machines and even whole production lines with functions to analyze and optimize operations.

Some serve as the processor for I/O signals providing feedback on speeds, temperatures, torque, tension, and more to optimize processes. Here, HMIs provide global insights based on myriad edge devices — those motor-feedback devices, transducers, sensors, and other smart components (such as smart motors or smart bearings) fitted with electronics to communicate current states. Other variations put HMI functionality right on the motion and other automation devices themselves. In fact, HMIs assume many of the tasks associated with legacy distributed control systems or DCSs. Refer to Design World’s literature on controllers (motion, PLC, PC, and PAC) for more on this.

Maple Systems now offers the cMT Smart HMI series that enables control and monitoring of the HMI from Windows PCs as well as and Apple and Android smartphones and tablets. Technological advances in IT, personal electronics, and manufacturing are expanding the role of HMIs in automation. HMIs must network to a central location where managers can monitor operations, receive alerts, and resolve issues quickly. OEMs need the ability to monitor and track in-field equipment, responding without costly onsite visits. Machine operators need freedom to walk the plant, controlling machines via tablets and smartphones. Now Maple Systems cMT HMIs enable these functions. Two new Smart HMI models include a powerful displayless HMI (cMT-SVR) and a 15-in. touchscreen HMI (cMT5151) with features for trending, recipes, alarms, and more. Both models also support MQTT, OPC UA Server, MySQL, and Modbus Gateway IIoT protocols.

As the effect of Moore’s Law shows influence on the advancement of electronic-display technology, today’s HMIs also assume all processing for the presentation of human-readable information about machines and automated operations. In fact, the task of processing data for human-readable readouts is something industry now takes for granted. Communications with machine controllers are also standard; many hardware iterations have yielded to software for executing communications-related tasks. Low-cost and free drivers abound. Here, the main decision design engineers may face is choosing between integrated options or ever-more-common Ethernet, fieldbus, or simple and cost-effective serial communications.

Open-source modules and easily configurable HMIs let designers use programming software for quick setup and customization. Templates allow configuration for collection of networked-machines’ data — and then navigation layouts to allow HMI end users (on the plant floor or elsewhere) to access all of those data streams in a logical way.

Pro-face America now offers an expanded SP5000 series modular HMI family. New options include screens with widths of 15 in. and 19-in. Both the 15-in. screen and 19-in. screen come with an enhanced glass-top design that boosts visualization and durability. The intuitive P-CAP touch-panel operation detects five touch points at once and features Touch Cancelation to prevent unexpected detections by water, or dust. A variety of Windows applications on WES7 can run with the HMIs thanks to an enhanced Open Box rear module. The new SP-5B41 Open Box unit comes standard with Pro-face’s HMI Runtime, and offers twice the CPU computing power, three times the storage space, and twice the data-access speed than its predecessor.

In fact, HMIs are core components in the industrial IoT, IT/OT convergence, and overall integration of plant operations with enterprise-level management. They can give machine operators detailed information on one running machine cycle; send workers and plant supervisors statistical analysis of throughput; replace printed paper charts on facility bulletin boards; and grant plant managers remote access to global data from smartphones and mobile devices. In fact, many HMIs filter data upfront for its ultimate destination and authorized audience.