Human Machine Interfaces
Human machine interfaces in the Industry 4.0 era
By Robert Davies, marketing manager, EAO A
Human Machine Interface (HMI) enables a human to interact with a machine. HMIs range from simple on/off switch panels to an extensive software
/ hardware-based SCADA system found at the heart of factory automation. HMIs are widely used in manufacturing where easy-to- understand visual displays and switches give meaning and context to equipment status and to highlight actions the operator needs to make, with a focus on intuitive operation and ergonomic design. In addition, today’s HMIs have a vital role in enabling line operators, managers, and supervisors to translate complex data into useful information.
Electromechanical devices such as pushbuttons, emergency stops, selector switches, keylock switches and optical and acoustic signalling devices remain an important component of most HMIs. The popularity of pushbutton operated devices is undiminished: They’re easy to install, intuitive to operate, provide distinctive tactile feedback and deliver a long service life. The convenience, safety, robustness (up to IP69K) and reliability of push-button
devices will ensure their popularity far into the future.
Able to accommodate important push- button operator control functions such as on/ off, up/down and emergency stops EAO’s Smart Box modules use a standard M12 connector to simply snap-onto a standard DIN rail alongside other important control gear such as timers, relays and PLCs.
Recent developments HMIs have evolved significantly over the last decades: Industry 4.0 is influencing HMI transformation, driven by technological advances such as the
28 November 2021
Internet of Things (IoT) and artificial intelligence (AI), enabling today’s machine operators to be part of co-critical decision making within the manufacturing process. With enhanced touch interfaces, voice and gesture controls and VR/AR tools, the interface between human and machine is driving digital automation and promising to bring benefits to smart factories through improved efficiency and decreased downtime. Industry 4.0 is therefore leading OEMs to adopt radically new approaches to machinery design and the incorporation of new technologies into HMIs.
Modern HMI technologies Smart hygienic switching
The increasing use of digitally networked machinery calls for systems to be intelligently connected to higher level bus systems and PLCs. When used in food and beverage production, such HMIs benefit from the use of smart switches and sensors
later on in the evolution of Industry 4.0, especially in conditions where remote operation of machines is needed.
that can be thoroughly cleaned to reduce the risk of contamination. EAO’s new Series 84 IO-Link touch-operated switches are crevice-free and jet-wash sealed to IP69K.
Touch-screen displays
Touch-screen displays have developed significantly since their introduction around twenty years ago, becoming more powerful yet more user-friendly. Modern touch interfaces offer multi-point operation and enable safe management of a machine even when ambient conditions mandate the operator wearing cumbersome PPE.
Voice interfaces
Voice interfaces typically facilitate data access through intuitive and efficient hands-free interactions. Voice-activated interfaces will become indispensable
The four industrial revolutions explained
First industrial revolution Starting in 1765 the original industrial revolution (Industry 1.0) transformed economies from agriculture to industry. The discovery of coal and the invention of the steam engine completely changed the way goods were produced. Canal transportation began to replace the horse and cart for moving the goods around.
Second industrial revolution The second industrial revolution (circa 1870) revolved around the discovery of gas, oil, electricity and the advent of mass production. By the beginning of the 20th century, electricity replaced steam-power, increasing assembly line effi ciency. The invention of the telegraph and later the telephone improved communications, whilst the combustion engine drove improvements in transportation.
Components in Electronics
Third industrial revolution The late 1960s saw the broad application of electronics and information technology to achieve further manufacturing automation. Technologies such PLC’s, bus systems and data analytics were key Industry 3.0 drivers. The fi rst commercial use of nuclear power is also considered a defi ning milestone.
Fourth industrial revolution The term ‘Industry 4.0’ was fi rst used in 2011 to describe smart manufacturing but later came to span transportation, smart buildings and renewable energy technologies. Digital networking of machinery and processes, smart sensors with IoT connections for remote diagnostics and control, along with robotics and AI have also become key drivers of Industry 4.0.
Bus based switches
Traditionally HMI systems are connected using hard-wired, point-to-point connections. In contrast, modern pushbuttons and signalling devices are increasingly being connected via serial bus communication cables to central control systems. These pluggable, message-based communications protocols reduce initial wiring time and make system expansion/ fault detection much simpler, and have proved to be a convenient and speedy way to commission driver/operator controls in trucks and buses and for the management of important auxiliary control functions in specialist and heavy-duty vehicles such as fire appliances, cranes, earth-movers etc. EAO offers centrally connected keypad, joysticks and switch modules specially developed for demanding vehicle applications. The company’s Series 09 includes both Controller Area Network (CAN) Bus and lower cost Local Interconnect Network (LIN) Bus connected variants.
Modern HMI design considerations The goal of the HMI designer is to produce a user interface that enables digital connectivity, and is easy, efficient, and user-friendly to operate. Design considerations in the era of Industry 4.0 involve ergonomics, haptics, consideration of the operating environment - temperature, and resistance to water, dust or vibration - and enhanced operator safety. Appropriate consideration of these and other operational requirements will guide the HMI designer to make the proper selection of HMI components, spanning functional and visual design and construction materials used.
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