The human machine interface (HMI) is vital for industrial automation and control systems. It changes how people work with machines and processes.
Table of Contents
Understanding Human-Machine Interface (HMI)
Human Machine Interface (HMI) is a complex technology that enables seamless communication, monitoring, and control interactions between human operators and machines in industrial settings. HMI comprises a wide range of hardware and software components, each of which contributes to the establishment of an efficient, user-friendly, and highly productive work environment in various industries.
How HMI Technology Works
HMI systems act as an important link between operators and machines or processes in industries, helping them communicate and control things effectively. Let’s take a closer look at how HMI technology works:
- Gathering Information: HMI systems collect information from a bunch of sensors, PLCs (Programmable Logic Controllers), and other machines used in industries. This data includes important details like the machine’s status, temperature, pressure, and other things.
- Working with Data: The HMI software carefully processes and organizes the collected data. This part involves keeping track of data, looking at trends, and managing alarms so that operators get useful information they can act on.
- Seeing things in your mind: The HMI touch display shows the processed data in a visual way. Operators can check how machines are doing, look at graphs that show what’s happening, and get instant updates about what they’re doing.
- Control: Workers use the HMI touch panel to give commands to machines, change settings, and quickly react to alarms or problems.
- Talking and sharing ideas: HMI systems often talk to bigger control systems like SCADA (Supervisory Control and Data Acquisition) or MES (Manufacturing Execution Systems) to share information, which helps with central control and monitoring.
- Logging In: In situations where safety is really important, HMIs might need users to log in so that only people who are allowed can use and control the machines and processes.
The Role of HMI in Industrial Automation
The human-machine interface (HMI) is important in shaping the landscape of industrial automation for several compelling reasons.
- Enhanced Efficiency: HMI panels enhance operations by providing a user-friendly interface for monitoring and controlling machinery. This leads to increased productivity, reduced downtime, and optimal resource utilization.
- Increased Safety Standards: Operators may respond quickly to alerts and safety concerns using the HMI, reducing possible hazards and creating a safer work environment for everybody.
- Data visualization: HMI touch displays show complicated data in understandable formats, allowing operators to make informed decisions in real time.
- Remote Accessibility: Many HMI systems feature remote monitoring, which allows operators to monitor processes from anywhere. This feature improves operational flexibility and responsiveness.
- Customization and adaptability: HMI interfaces are extremely adaptable, allowing operators to tailor them to specific requirements while ensuring smooth integration into diverse industrial environments.
How HMI Work in SCADA Systems
Most SCADA systems, which stand for Supervisory Control and Data Acquisition, use built-in HMI parts to work well. The SCADA system is the main control system in a factory or plant. It manages and regulates all the complicated operations happening there.
In the past, a programmable logic controller (PLC) was required to link the human-machine interface (HMI) to a manufacturing line. The HMI would show the information it got from the PLC and also send input from users back to the PLC. These graphs were usually really easy to understand.
The basic HMI lets the operator or plant manager see important things like the temperature of the machines, how many items are being processed, the status of the machines, and the amount of materials used.
An Example of HMI and SCADA in Real Life
In a typical situation, you can find an HMI being used in lots of water and sewage treatment plants. These facilities usually have a hard time because water treatment includes many steps like screening, pumping, and getting rid of harmful germs and leftover materials. Each part of the treatment can happen in places that are really far apart, like several kilometers away, so keeping an eye on the equipment and processes is tough.
The HMI screen that is part of the SCADA system is typically linked to the PLC. This allows the operator to check things like water level, pH, water pump status, the amount of dissolved solids, or certain toxic chemicals from a distance.
You can turn the water pump on or off depending on how full the tank is by using the Human-Machine Interface. The HMI also shows alerts when the pH drops below a specific level, and you can change this using the touchscreen display. The HMI helps the operator keep an eye on and manage the different steps of water treatment.
Lots of new industrial HMIs being made for smart factories have a lot of multimedia features. Users can get SMS alerts about how machines are doing, email alerts, and even watch videos of what’s happening on the factory floor. Advanced HMIs let you control several machines from far away and manage operations at different locations, plus they help analyze how the factory is running. HMIs can show dashboards that include important numbers and information about manufacturing and the plant.
The role of the HMI is changing quickly because new technologies keep getting added in.
Important Reasons to Invest in a High-Tech HMI for a Factory
Right now, there are a lot of really advanced HMIs available that help people keep an eye on and control machines in factories. The biggest advantage of investing in a high-level human-machine interface that can do things like monitor machines from far away and show important data on dashboards is that it makes factory processes and operations easier.
Another big advantage is being able to access important, real-time information easily. The features of today’s advanced HMI really help make the factory environment less complicated.
Also, factory owners can easily react to new or tough situations by using the Human-Machine Interface. This means that things work better because there is less time when they are not working. This helps the factory owner use smart systems that cut down on costs and waste, making processes better and increasing profits.
In the future, HMIs at the edge or on the machine will become stronger and will be able to compete in real time.
Should I create or purchase the HMI?
Factory owners often wonder, “Should I make the HMI myself or buy it?” This question is really wide-ranging, and there isn’t just one easy answer because there are a lot of different factors to think about. Here are a few questions you might want to consider:
- What processes and operations does the HMI have to manage in the factory?
- What machines and settings should we keep an eye on in the factory?
- How complicated does the HMI have to be?
- Does the business have its own experts and knowledge?
- Does the factory owner have enough time to work on the design, development, and testing of the HMI?
- The market requires companies to quickly update their products, and they need to think about whether they can do this on their own.
- The market also pushes for quick technological improvements, so the same idea applies.
- Can we use outside technology with our current development teams?
- How much money do we have to spend?
- What are the final goals? Is it just a basic prototype for a research project, or do we want a complete and fully functional version of an HMI?
If the factory owner or manufacturer doesn’t know how to design, develop, and build HMIs, it’s usually better to just buy them instead. This will help us save time and provide a solution that has already been tested. Before a manufacturer or factory owner starts designing their own HMI, they should definitely do some research and talk to a consultant or expert.
The Future of How Humans and Machines Work Together
Right now, there are a lot of guesses about what the future will look like for how humans and machines will work together. Technologies like cloud computing, cognitive computing, and the Internet of Things (IoT) are all likely to be important in how humans and machines interact in the future.
It’s tough to guess what will come next in terms of getting people involved. But it’s clear that there will be a new stage of teamwork between humans and machines that will boost productivity in different industries.
With the rise of Industry 4.0, industrial HMIs will start to include more new and emerging technologies that are affecting HMIs overall.
