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Partnering August, 2014 Interface Design Involves Highest Levels of Complexity By Ed Sullivan


sign of the human-machine interface (HMI) for those products can often be as instrumental to the success of those products as the design of the product’s main functionality. Effective HMIs have contributed to the success of a wide range of products, from popular consumer electronic products to the most advanced military and aerospace equipment. Aerospace applications range


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from cockpit controls and displays and cabin environment controls to in-flight entertainment systems. HMIs are used throughout defense electronic systems, whether for shipboard, air- borne, or ground mobile applications, such as hand-held computers, high- resolution monitors, and secure voice/data communications devices. Because of their exposure to harsh en- vironments and rough treatment, these products often require ruggedi- zed HMIs.


Having the Correct Interface “You’ve got to have the right in-


terface for the right application,” says Hemant Mistry, president of Jayco MMI (man-machine interface) of Coro-


oday’s electronic products may often combine clever use of dif- ferent technologies, but the de-


na, CA. “HMIs for defense and aero- space applications must be designed to improve cognition and comprehension to enable rapid decision-making. Thus, it is essential that not only is informa- tion clearly presented, but that inputs to a system are easy and intuitive to make in order to eliminate errors in stressful situations.” While an HMI might be consid-


ered an integral part of a product (which it ultimately becomes), the de- sign and manufacture of the interface is often a separate, specialized process that involves the highest levels of com- plexity, both human and technological. At the same time, build-to-print HMI designs created without the collabora- tion of an interface specialist are al- most always fraught with problems. Developing a successful man-ma-


chine interface involves design sub- tleties, such as ergonomics, psychology, and other “user-centric” considerations. It may also involve a choice of materials and interface technologies, the need to perform in harsh environments, and the need to fit within limited space on smaller products. Whether an interface is display-


ing information, collecting data, or con- trolling operations, it may require spe- cial design consideration such as


ruggedized features or the integration of multiple elements. These are among the many design challenges faced by de- velopers of HMIs.


Avoiding Design Pitfalls Improper design of an HMI can


render a product ineffective. As an ex- ample, video cassette recorders (VCRs) were consumer products designed to revolutionize


television viewing


habits, but they offered interfaces that discouraged users from even setting the time. Other newly developed con- sumer, scientific, and industrial prod- ucts have also been compromised by user-unfriendly interfaces. One exam- ple is requiring the use of touch screen typing, which is considerably more dif- ficult than keyboard typing, particu- larly in turbulent or bumping condi- tions. When developing professional equipment for critical applications, the design of the most appropriate HMI has become even more challenging. Given so many available inter-


face solutions available, it is difficult for most product designers to deter- mine which switch and display tech- nologies are appropriate, which control modalities should be used, which func- tions require direct user access, which materials and construction techniques are optimum, and how different engi- neering constraints may influence both design and costs.


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Complete Documentation Needed Experienced engineers with


knowledge of HMI solutions often pro- vide complete documentation for their designs. While these approaches may be excellent, they may also represent lost opportunities for cost reductions and other benefits when not consulting with HMI experts. According to Keith Henzig, Vice-President of Engineering at Secure Communication Systems in Santa Ana, CA (www.securecomm. com): “There are serious challenges in- volved when customers build-to-print their own interface designs. Those in- clude possible errors requiring re- design and additional time and money. Also, depending on the application, re- liability is always a key constraint.” Heinzig notes that his firm’s en-


gineers are not open to compromises that may impact reliability. The com- pany provides custom rugged comput- ers and custom contract manufactur- ing solutions for defense, aerospace, and industrial applications that in- volve extreme environmental condi- tions. He explains: “Our systems can be found in the hands of troops and on vehicles all around the world. “Our commitment to providing high levels of service and quality has made us a long-term partner to many manufac- turers in the defense industry.” The company specializes in commercial-off- the-shelf (COTS) equipment that is cost-effective and reliable. Jayco’s Mistry offers that from an


interface developer /manufacturer’s perspective, the built-to-print ap- proach carries with it certain avoid- able risks: “In most cases, a build-to- print HMI requires re-design, re- thinking that can be unnecessarily ex-


pensive and delay product releases.” His firm specializes in extreme appli- cations for defense, aerospace, and other sectors, and is capable of han- dling extremely complex design work, utilizing virtually any available inter- face technology from mechanical switches to touch panels. Mistry, whose company designs


and builds equipment to meet or exceed military standard (MIL STD) require- ments, views HMIs as key systems within a design, not just a component. Through early involvement during a system’s design phase and integrating an HMI’s components into a complete subassembly, including enclosures, dis- plays, switches, and electronics, a high- performance HMI can be developed that will be easier for an end-user to manage and integrate into their sys- tem. He points out that the most effi- cient and effective approach to HMI de- sign usually involves a team approach that includes the product engineering staff as well as the interface supplier. Such a consultative approach can re- duce product development time and costs while solving complex problems with superior solutions and packaging. Mistry says: “By working togeth-


er the team can ensure that all of the relevant ideas are thoroughly ex- plored, and that various manufactur- ing issues are taken into account.” He adds: “I think the best HMIs are actu- ally simple and intuitive,” he adds. “But to make them simple and intu- itive is not easy. What is required is a thorough understanding of the appli- cation, an understanding of the envi- ronment that the product is going to be used in, and the technologies that are available to achieve the end.” A major concern in military and


aerospace applications is ensuring that interface devices are ruggedized for ex- treme environments. This includes pro- tection from corrosion, providing for military-grade shielding, protection against shock and vibration, contami- nate sealing, sunlight readability, night vision lighting, and extended-life grade products. As Heinzig explains: “We have worked successfully with Jayco for a number of years, and their prelimi- nary design consultation has been very helpful in keeping us on the right track as far as planning and implementing the HMIs for our products. Some of our more recent projects include very small controls, such as wrist displays for the military.” Jayco often provides a digital or


virtual prototype for a customer to see a proposed solution. Heinzig explains: “The trend today is that products have to be smaller, lighter, and use lower power. Yet, you somehow have to find room to squeeze some HMI controls onto the equipment, and that gets more difficult as product sizes continue to be reduced.” He summarizes that finding room for HMI controls often requires


creativity and advanced planning. Contact: Jayco MMI, Inc., 1351


Pico St., Corona, CA 92881-3373 % 877-529-2648 or 951-738-2000 fax: 951-738-2010


E-mail: hemant@jaycopanels.com Web: www.jaycopanels.com r


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