TECHNOLOGY HANDBOOK
A LOOK INTO THE PRODUCTS, TECHNOLOGIES AND AN SOLUTIONS SHAPING THE MARKET
HMI & OPERATOR INTERFACE
DIGITAL
SUPPLEMENT TO
MACHINE DESIGN • SYSTEMS • TECHNOLOGY
TECHNOLOGY HANDBOOK
HMI & Operator Interface
Advantech Industrial Automation
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he evolution of operator interfaces has moved quite far beyond the push button technology. Once, the intelligence resided in the operator’s brain and considerable experience and training were required to operate any complex piece of machinery or process. The evolution of the operator panel is actually two parallel tracks. First is the movement of that intelligence from the operator’s brain into the operator panel itself. So, we now refer to them as “smart operator panels”. The other track is how the evolution of the operator panel tracks Moore’s Law, making them incredibly more powerful and less expensive over and over. Smart operator panels permit the operator to have access to large amounts of information in one location, on one or just a few screens. This may include process data, quality data, performance of the cell, unit or batch, as well as controls for the system themselves. What is a Smart Operator Panel? It’s a computer – an embedded computer complete with input/output, memory, a processor, and a display in an enclosure that is suitable to the environment the panel will be used in, from rack mount to enclosures that are waterproof or explosive proof. It serves many functions formerly handled by multiple devices. It is a control panel, with push-button analogs and displays. It can be used as a data-logger, and sometimes a sequence-of-events recorder, and can provide “help” functions that can assist operators with decision support.
Advantech WebOP Series Advantech offers Operator Panels which are designed with RISC platform and provide real-time OS and built-in Microsoft ® WinCE 6.0 OS platform bundled with Advantech’s WebOP Designer software, an easy to use integrated development tool featuring solution-oriented screen objects, high-end vector graphics, Windows fonts for multi-language applications, recipes, alarms, data loggers and operation logging.
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WebOP Designer software also includes online/offline simulation and other utility programs such as Data Transfer Helper (DTH); recipes editors and text editors. WebOP runtime, a part of WebOP Designer, guarantees reliability and performance because of the minimum system overhead, high communication data rates, sub-second screen switching, and 24/7 operation. The Operator Panels are compact flatsealed, waterproof, with IP66 rating and 0 to 50C operating temperature range and level 4 ESD protection. They come in a variety of LCD sizes from 3.5” to 12.1” with 512MB on board SLC type storage and 128KB backup FRAM. They support independent isolation design and have a built-in CANBus function. There’s a standard Micro SD slot for static data storing use. With various communication interfaces, including RS232/422/485, Ethernet and USB ports, these Operator Panels can easily connect to a variety of equipment. Also, they are compatible with over 300 of the most popular PLCs on the market, including: Allen Bradley Micrologix, CompactLogix and ControlLogix, Modicon, Quantum, GE 90, Siemens AG Simatic S7, Mitsubishi. FX/Q, Omron Sysmac FINS/TCP, C/CV/CS/CJ, and Yaskawa MP, the WebOP series and WebOP Designer software provide an outstanding price/ performance ratio for a variety of factory automation needs. They come in the WebOP-2000 and 3000 series. Visit Advantechs’ WebOP Minsite for much more information.
Advantech Industrial Automation 11380 Reed Hartman Highway, Cincinnati, OH 45241 Toll Free: 1-888-576-9668 Phone: 1-513-742-8895
www.advantech.com
Rugged and Reliable Operator Panels
A wide variety of flexible operator panels to meet every application need • Wide selection of LCD sizes • Flat front panel with IP66 rating • Built-in remote monitoring capability • Supports over 350 PLC communication protocols
WebOP-2000 Series Purpose-built panel with HMI runtime included • 4”-12” size LCD screens • Remote management tools • Free development software
www.advantech.com
WebOP-3000 series PC-based panel with optional HMI runtime • 7”-12” size LCD screens • Supports Windows CE, Linux, and Android OS • Program in .NET or HMI software • Wide operating temperature
TECHNOLOGY HANDBOOK
HMI & Operator Interface
Power Panel, Safety, Motion and HMI controller
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&R has added two new series to its successful Power Panel HMI family: Power Panel T-Series terminals and Power Panel C-Series controllers – both featuring analog resistive touch screens. Equipped with an embedded browser, Power Panel T30 terminal devices are fully web-compatible and can even be used as a Visual Components client. The terminal series is being offered with four TFT display sizes ranging from 4.3” to 10.1” and comes with 2 Ethernet interfaces, 2 USB ports and an extensive array of configuration options. The Power Panel C70 controller is equipped with a 333 MHz Intel Atom CPU, 256 MB DDRAM, 16 kB FRAM and 2 GB onboard flash drive. This controller provides a built-in touch screen and is being offered in three display sizes ranging from 5.7” to 10.1”. The Power Panel C70 achieves cycle times down to 1 ms. POWERLINK and standard Ethernet, 2x USB 2.0 and X2X Link, as well as optional RS232, RS485 and CAN interfaces meet all connection requirements. Both of these device series have an extremely compact design, minimal installation depth and an intelligent cable outlet arrangement, making these panels easy-to-mount space savers. And because these two new series do not have hard disks, fans or batteries, they are maintenance-free. The panel front provides IP65 protection, which makes these devices extremely well-suited for harsh industrial environments.
with either HD Ready or Full HD resolution. The larger displays and higher resolution make it possible to include even more information on each screen – an enormous advantage for user ergonomics. If space is limited yet large displays are still necessary, a 21.5” model in portrait format is also available. With optional side handles, it is easy to maneuver and operate these devices at the machine. Two system variants with analog resistive touch screens are also available in 4:3 format, allowing users to upgrade their operator hardware without having to modify their existing HMI applications in any way. These panels are connected using affordable standard cables run conveniently through the swing arm shaft – even after mounting. And for those who choose Smart Display Link 3 – which allows up to 100 meters between the PC and panel – the slim RJ45 connector makes cabling even easier. These swing arm systems can be equipped with buttons, selector switches, key switches and an integrated E-stop button as needed. Thanks to an integrated RFID reader, individual access rights can be assigned to anyone from service engineers to system operators. Jotting down passwords on small scraps of paper has been relegated to the past – right where it belongs. Learn more about swing-arm panels
Learn more about the C-/T-Series Swing arm systems with IP65-rated panels raise the bar B&R recently introduced a new line of swing arm systems that includes fully enclosed panels available in a wide range of variants and feature IP65 protection, allowing them to be placed optimally on machines. Multi-touch widescreen panels are available in sizes ranging from 18.5” to 24”
4 MA • Technology Handbook HMI & Operator Interface
B&R Industrial Automation Inc. 2501 Rutherford Road, Unit 42-43 Concord, ON, L4K 2N6 CANADA Tel: 1-905-417 9500 Email: office.ca@br-automation.com
www.br-automation.com
ALL SHAPES. ALL SIZES. ALL COLORS. www.br-automation.com/PowerPanel
< PLC + HMI = Power Panel C-Series < Pure HMI = Power Panel T-Series < For I/O, drives and safety < POWERLINK | Ethernet | USB | CAN | RS232 | RS485 < 4,3" | 5,7" | 7" | 10,1"
TECHNOLOGY HANDBOOK
HMI & Operator Interface
High Techtech Solutions for afor High Tech World High Solutions a High Tech World
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HMI Efficient and Reliable HMI Efficient and Reliable
he goal of HMI is the efficient HMI c o he n tgoal r o l of o f ais the efficientfrom control machine the of a machine from o p e r a t o r s e n d the operators end while the interface giveswhile the interface gives immediate immediate feed back that back that the operator the feed operator needs to needs to make make decisions decisions in the in the process. HMI be used process. HMI can becan used in a broad range of interface in a broad range of interface applications such as robotics and applications such as robotics heavy operator controls that control and andmachinery heavy machinery operamonitor the I/O,that motors, robotics tor controls control and and drives.
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liability and the availability of your network backbone. The EDS-G500E series is The EDS-G500E equipped with 8/12/16series is designed Gigabit Ethernetespecially ports for communication demanding and up to 4 fiber optic such as ports, applications, making it ideal forvideo and process monitoring, upgrading an existing ITS, and a DCS systems, network to Gigabit speed or building new full all of which can benefi t from a Gigabit backbone. 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Unlike traditionalofRTUs, are pasthis happen the happen operator would provide the minimal backbone. The poll EDS-G500E series isE2200 designed operator provide minimal inputneeded go towith get the theHMI sive and must for data, Moxa’s ioLogik series with input would go to get the maximum output communication demanding maximum needed with the HMI reducing especially Active OPCfor Server makes seamless connection with SCADA reducingoutput undesirable outputs to the operator. applications, such as video and process undesirable outputs to is the operator. systems a reality. In addition, SNMP is usedmonitoring, for communicatThe HMI system interfaced with industrial equipment ITS, ing andwith DCS systems, all ofManagement which can System) benefitfor from an NMS (Network IT field and communicates through an Ethernet backbone. Moxa’s a scalable backbone construction. The Ethernet HMI system is interfaced with between industrial users. The I/O status of an Ethernet micro RTU controller switches provides communication all eleequipment and communicates can be reported and controlled automatically on-site based on ments within the HMI process. through an Ethernet Moxa’s E2200 isThis a new type of Ethernet backbone. Ethernet user ioLogik specified conditions. report-by-exception approach, Moxa’s Moxa's EXPC-1319’s display forswitches interfacing provides with the operamicro RTU controller, which is a PC-based communication between all elements within the HMI which is new to PC-based monitoring, requires far data less bandtor has features that are build upon rugged durability, making acquisition and controlpolling devicemethods. that uses proactive, process. width than traditional it ideal for use as an HMI terminal, or as a secure computevent-based reporting to control I/O devices. Unlike ing platform for control applications. The standard EXPCtraditional RTUs, which are passive and must poll for Moxa's display for interfacing 1319EXPC-1319’s comes with a high-performance, dual corewith Intel the 1.8 GHz data, Moxa’s ioLogik E2200 series with Active OPC operator has features that are build upon rugged Atom D525 CPU that combines lightning processing speed Server makes seamless connection with SCADA durability, making for use The as an1000 HMInits terminal, with low powerit ideal consumption. LCD panel systems a reality. In addition, SNMP is used for or as a secure computing platform for control comes with anti-glare technology to guarantee that informacommunicating with an NMS (Network applications. The standard EXPC-1319 comes with tion is presented and clearly visible even under direct sunlight. a high-performance, dual core Intel 1.8 GHz Atom Management System) for IT field users. The I/O Additionally, the scratch resistant screen makes it possible for D525 CPU that combines lightning processing status of an Ethernet micro RTU controller can be workers wearing protective gear to manipulate controls withspeed with low power consumption. The 1000 nits reported and controlled automatically on-site based out worrying about with damaging the display. LCD panel comes anti-glare technology to on user specified conditions. This report-byThe EDS-G500E series is equipped with 8/12/16 Gigabit exception approach, which is new to PC-based guarantee that information is presented and clearly Ethernet ports and up to 4 fi ber optic ports, making it ideal Manufacturers Automationfar Inc. less bandwidth than monitoring, requires visible even under direct sunlight. Additionally, the for 1600 Kingpolling Street North, St. Jacobs, ON NOB 2N0 upgrading an existing network to Gigabit speed or building methods. scratch resistant screen makes it possible for traditional a new full Gigabit backbone. Gigabit transmission increases Toll free: 1-800-387-6268 email: sales@manuauto.com bandwidth for higher performance and transfersInc. large amounts Manufacturers Automation 1-800-387-6268 • www.manuauto.com of triple-play services across a network quickly. Redundant www.manuauto.com
6 MA • Technology Handbook HMI & Operator Interface
HMI: Industrial Computers, Ethernet, I/O, and Displays
Outstanding Quality Outstanding Reliability Industrial HMI Computer & Display
Industrial Ethernet Switches
Industrial Computing
Industrial I/OLogik
How May We Help You?
Manufacturers Automation Inc. 1600 King Street North, St. Jacobs, ON N0B 2N0 - 1-800-387-6268 - www.manuauto.com
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TECHNOLOGY HANDBOOK
HMI & Operator Interface
Finding an HMI with Integration Advantages
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mart operator interfaces provide a window into machine operations as well as serving up diagnostics and corrective steps that ultimately translate into efficient productivity. However, selection of the HMI often gets treated as an afterthought once overall machine functionality is settled. The task of selecting a compatible HMI and integrating it for optimal operator usability consumes time that can delay machine delivery. The way to shorten the process is choosing an HMI with built-in integration advantages. The Design Challenge As the design of new automated equipment takes shape, decisions are made about the type of control system to be used. Vendors often are reviewed on a variety of factors. There may be some needed features and functionality only available on a particular control system which in turn could drive the decision process. Some designs are based on the design team’s familiarity with a particular control element that becomes the centerpiece of a control system wrapped into a solution with a variety of components. One vs. Many The success in translating a control solution into reality hinges on vendor selection and the complexity of integrating their hardware and software. Here are some common selection pitfalls to avoid: • Control system designers may go with an automation solution based on what they are familiar with and not take into account the capability of the system to include or integrate needed accessory products, such as HMIs. This can lead to less than optimum performance once the equipment is deployed. • If a particular feature of the automated equipment is deemed “significant”, such as motion control, that feature could drive the decision in one direction, perhaps not taking into account the overall performance of the system.
8 MA • Technology Handbook HMI & Operator Interface
• Selecting components from various suppliers to create an automation solution may have the highest total cost of ownership of any other choice. Integration costs may be higher, time to deployment may be longer, and support costs from a variety of vendors may be higher. Sysmac Platform Solution Designed to simplify integration of the most challenging aspects of machine automation, Omron’s Sysmac platform integrates Logic, HMI, Motion, Vision, Safety, Robotics, Sensing, and Database functionality in one control system. The integrated development environment of Sysmac Studio software reduces programming and configuration time, eliminates multiple license maintenance, and streamlines technical support to a single point of contact. One common software package supports all Sysmac platform equipment. The NA-series HMIs with high resolution wide screens from 7 to 15 inches are optimized to integrate with Sysmac platform products including: NJ-series machine automation controllers, G5-series servo systems, MX2- and RX-series frequency inverters, pick-and-place delta robots, FH and FQM1 vision systems, NX-S safety controller and motion products, Sysmac Studio software. Learn more about the integration advantages at Omron’s Sysmac Platform on the Products tab of our website.
Omron Automation & Safety 885 Milner Avenue Toronto ON M1B 5V8 Toll Free: 1-866-986-6766 Email: askomron@omron.com
www.industrial.omron.ca
Try the Hassle-Free Way to Integrate Machine Controls
When you need to integrate any combination of Logic, Motion, Robotics, Vision, Safety, Sensing, and Enterprise, choose the one automation platform that can do it all — without multi-vendor complexities. Under one programming environment you can design, configure and commission a complete
machine automation system. Omron’s innovative Sysmac architecture drastically reduces machine tact time and programming complexity, while improving performance and speeding development. Leverage the high-speed, EtherCAT machine network and EtherNet/IP factory network to take the limits off your throughput.
Explore the Sysmac Automation Plan at omron247.com OMRON AUTOMATION AND SAFETY • Canada toll free: 866.986.6766 • www.omron247.com
TECHNOLOGY HANDBOOK
HMI & Operator Interface
Imapsa Automation Modernizes Outdated Rice Filling Packaging Machinery with Unitronics’ new Samba.
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ith locations in both Guatemala and Honduras, Imapsa Automation specializes in preventative maintenance engineering. In this particular application, they are focusing on automating rice filling and packaging machinery. Imapsa is always looking to give their customers not only a reliable system, but a great looking customized display. At the time, their rice filling and packaging machinery was in desperate need of modernization. In order to hold true to their commitment to quality and reliability, they needed to find a way to reduce the set-up time and build a more flexible system. The timing for the different steps of the filling process was originally made mechanically by a camshaft with 7 cams and 7 micro-switches; this process needed to be more efficient. Impasa also needed the ability to give information to their production department to track the efficiency of the machine and the operator. Unitronics’ Samba SM35-J-T20 was ultimately chosen for the task. The drum sequencer command and the high speed (encoder) inputs of the SM35-J-T20 were the key ingredients that made automating this machine easy and effective. In the past, when the operator would change the type of rice bag for different brands of a final product, making adjustments required the mechanical and manual adjustments of the cam and micro-switches. Now, with the Samba, the operator can simply adjust the machine by entering and changing the
10 MA • Technology Handbook HMI & Operator Interface
degrees of the electronic cam. The 3.5” color touchscreen and the resolution also allowed them to design great looking displays that were easily understood by the operators. The PLC also gave them the much needed ability to send reports to the production department to track the efficiency of the filling speed, the number of bags filled, the operating time, and a data table showing the start time and any stop time. “With fast delivery times, and constantly updated software, Unitronics has always listened to our customers many requests, and have implemented them since we decided to start our automation division in 2001,” said Ober Yela of Imapsa Automation. “Great support via both the technical support team and the Unitronics forum. And of course, great price!” To view a video of this application in action, please click below!
Unitronics Inc. 1 batterymarch Park Quincy, MA 02169 USA Tel.: 617-657-6596, Fax: 617-657-6598 Toll free: 866-666-6033 email: usa.sales@unitronics.com
www.unitronics.com
Powerful Software
PLC HMI
Outstanding Support Complete Range of PLCs
ALL IN ONE
3.5” 4.3”
7”
Features • 3.5”, 4.3” or 7” color-touch HMI Include: • Options for analog and digital I/O, including high-speed • Communications include Serial, Ethernet, MODBUS and CANbus • Full software suite for remote access, data logging utilities and more • Complimentary software and support
Tired of text display?
It's SAMBA time!
For OEMs looking for a competitive advantage, Unitronics offers Samba, a PLC with integrated HMI and I/O, starting under $400. Unitronics, Inc.
1 Batterymarch Park Quincy, MA 02169 USA Tel: 617-657-6596, Toll Free: 866-666-6033 usa.sales@unitronics.com, www.unitronics.com
TECHNOLOGY HANDBOOK
Manufacturers are harnessing mobile apps like never before BY ROBERT ROBERTSON
HMI & Operator Interface
REMOTE
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anufacturers are harnessing mobile app technology to improve product functionality and customer service, increase sales revenue and boost productivity on the plant floor. For example, Dearborn, Mich.-based Ford Motor Company has launched the new mobile app Ford Developer Program. It provides software developers with the information and tools needed for the creation of a relevant, voice-activated setting inside the car. Ford is now the first automaker to offer an open developer program, which enables software developers to directly interface with the vehicle and create mobile apps that will enhance the driving experience.
And the demand for mobile apps is growing at meteor speed among consumers and in the workplace. Apple recently announced customers have downloaded more than 40 billion apps (excluding re-downloads and updates) with nearly 20 billion in 2012 alone. The App Store has more than 500 million active accounts and had a record-breaking December in 2012 with more than two billion downloads during the month. Based on current smart device popularity, Stamford, Conn.-based consulting firm Gartner Inc. also reports there’s an opportunity for mobile app stores to generate 310 billion downloads and US$74 billion in revenue by 2016.
The demand for mobile apps is growing in manufacturing. Progressive manufacturers can create app “stores” with application capabilities that can be easily configured to match employee, business partner and customer roles.
12 MA • Technology Handbook HMI & Operator Interface
Mobility in manufacturing Sowri S. Krishnan, vice-president, mobility with New Jerseyheadquartered IT and consulting firm Cognizant, isn’t surprised the use of mobile apps is skyrocketing, especially among Millennials who access the Web using mobile devices. He says by combining existing technologies with a deep understanding of their business, progressive manufacturers can create app “stores” with application capabilities that can be easily configured to match employee, business partner and customer roles. Krishnan, who is based in Chennai, India, further says the use of mobile apps is set to change manufacturing as we know it today.
TECHNOLOGY HANDBOOK
HMI & Operator Interface
CONTROL “As both consumers and businesspeople, Millennials favour virtualized environments that allow them to communicate and collaborate anywhere and anytime. To fulfill this need, all businesses, especially manufacturers, must create enterprise-grade mobile apps that are simple and intuitive,” says Krishnan. “Mobile apps can increase workflow efficiency and productivity with approvals, submissions and analytics. Manufacturers can not only enact greater productivity, but also achieve better cash management. “One such mobile app allows senior manufacturing managers to view sales of their top 50 customers. Another app provides a days-sales-outstanding
(DSO) view of all customers, calculating the maximum discount a salesperson could offer to customers who exceed DSO limits. Mobility can be a key enabling technology for manufacturers that seek to advance information quality, reduce costs, increase revenues, as well as improve customer service and responsiveness.” According to Krishnan, enterprise mobility in manufacturing helps both discrete and process manufacturers by creating new and better efficiencies in their organization, driving down people and material costs and increasing asset utilization. It reduces errors and provides accurate data. The end result is increased profitability, raised
customer satisfaction and a strong competitive advantage. Krishnan says manufacturers have to apply the aspect of mobility to eliminate key waste areas within their environment, including over-production, waiting time, transportation, processing, unnecessary motion, defects and inventory. “Mobile apps create disruptive business and operating models that drive non-linear growth. This is particularly true of companies in emerging markets, where marketing and selling through mobile devices can be faster and less expensive than creating a traditional retail and sales network,” says Krishnan. “The manufacturing industry is moving quickly to adopt
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TECHNOLOGY HANDBOOK K mobility. A ‘one size fits all’ model, however, doesn’t apply to enterprise mobility. In terms of implementing mobile technology, it’s important for organizations to have a strategic vision and ensure they choose wisely.” Real-time access Diversified industrial manufacturer Eaton is successfully pushing ahead with mobile app technology. The company introduced the POWEREDGE mobile app that provides customers and channel partners with “real-time” access to its electrical catalogues, videos and training. POWEREDGE enables users to learn more about Eaton products, and to share that knowledge by emailing individual catalogue pages, entire volumes or videos directly from the mobile app itself. Users can also locate the closest channel partner to purchase Eaton’s electrical products. The POWEREDGE mobile app, which can be downloaded at the App Store free of charge, was designed to take full advantage of Apple’s iOS platform. “As the importance of the digital landscape continues to grow, information has to be available on demand. Mobile apps are helping customers and channel partners alike get information when and where they need it,” says Zari Talebi, global branding and integrated communications at Eaton. “The POWEREDGE mobile app is designed to help customers find information on solutions that improve the reliability, efficiency and safety of the systems they manage.” Software developer AutoLean offers the universal OEE Monitor app for Apple iPhone, iPad or iPod
HMI & Operator p Interface Touch systems to manufacturers, such T as Pactiv, Beam Global and Reynolds Packaging Group. The mobile app is available for US$2.99 and allows users to collect and calculate overall equipment effectiveness (OEE) from anywhere in the plant facility. Users aren’t tied to a desktop computer or need to be online. OEE Monitor is suited for longer-term Kaizen tracking improvements. Future versions of OEE Monitor will allow a cloud component where various real-time users can share data and compare OEE graphs. AutoLean also offers free Quick Takt and Quick OEE mobile apps for existing dashboards and more fast-paced calculations. AutoLean has its roots in Lean manufacturing and plans to have 12 Leanspecific mobile apps showcased in the App Store early this year. According to AutoLean director Jeff Jackson, one of the most powerful concepts of Kaizen is ensuring improvements are made quickly. As a result, having accessibility to tools and reports where change is being implemented is critical for manufacturers. To effectively support this, Jackson says it makes sense that some of these tools would come in the form of mobile apps. “Mobile apps in the manufacturing environment are still in the infancy stage. It’s really exciting to discuss their potential. Companies are discovering that iPhones, iPads and similar devices are excellent for the manufacturing floor,” says Jackson. “In most cases, you can have a device online and engaged in the workspace for an entire day. This new level of mobility can really open the limits on production cell design and streamline
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flow within the process. Reducing the waste of movement will undoubtedly improve your cycle time. “And it’s important to remember that Kaizen events are designed to drive out waste and process inefficiencies. Think about how your charts and reports could be eliminated and managed in the form of mobile apps. In terms of computing solutions for consumers and plant professionals, devices like iPads are quickly replacing desktops and laptops. Businesses of all kinds are naturally beginning to see how mobility greatly impacts employee engagement. It’s no exception when striving for continuous improvement in manufacturing, as you have to be ‘present’ where the process occurs in the plant.” The future is now According to Ralph Rio, research director with Dedham, Mass.-based ARC Advisory Group, manufacturers can make huge strides on the plant floor by going mobile, which leads to increased usage. “With a smart device, you’re able to improve information gathering and make more accurate, real-time decisions. Since lots of workers move about a plant while on the job, manufacturing is well suited for mobility,” says Rio. “However, it’s also well behind the curve. The most common mobile device is still a piece of paper. Many people have a smart phone or tablet, so, the mobile adoption rate is already high among consumers. In the future, we’ll see more manufacturers benefit from the technology.” h l Robert Robertson is a freelance writer based in Mississauga, Ont.
HMI & Operator Interface
TECHNOLOGY HANDBOOK
TMI from your HMI? How to deal with data overload BY IAN VERHAPPEN
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ll of us are aware of the amount of data available from modern control systems, their field devices and the algorithms used to infer additional information from that data. The challenge is managing and understanding that data by converting it first into information that we as humans can understand, and then into knowledge upon which we can take appropriate actions. We have learned a lot about how to display data since the introduction of the DCS and computer displays in the 1970s, when the display was a colour version of the Piping & Instrumentation Diagram (P&ID) with key process values shown numerically and electronic versions of strip charts to allow operators to observe process trends. We then “progressed” to Windows-based HMIs with even more distractions of spinning pump impellers, fluidized beds and all the wizardry of computer gaming at that time. Fortunately, research has shown simplicity and low-key use of colour is better, with this information being codified in the work of two ISA standards committees: ISA18—Instrument Signals and Alarms and ISA101—Human Machine Interfaces. From its purpose and scope on the ISA web site, the ISA18 committee “develops standards, technical reports and guidelines for alarm systems including annunciators, process automation systems and the general development, design, installation and management of alarm systems in the process industries. They do so by establishing terminology and practices for alarm systems, including the definition, design, installation, operation, maintenance and modification and work processes recommended to effectively maintain an alarm system over time.” In addition to updating the 2004 revision of the ISA18.1 standard on ‘Annunciator Sequences and Specifications,’ it is focused on the development of a series of technical reports on ‘Management of Alarm Systems for the Process Industries’ as part of the ISA18.02 standard set. Each of the six working groups are developing reports as follows: • WG1—Alarm Philosophy: Provides guidance for successful management of the alarm system. The resulting work will cover the definitions, principles and activities by providing overall guidance on methods for alarm identification, rationalization, classification, prioritization, monitoring, management of change and audit. • WG2—Alarm Identification and Rationalization: Addresses the processes to determine the possible need for an alarm or a change to an alarm, systematically compare alarms to the alarm philosophy and determine the alarm setpoint, consequence, operator action, priority and class. To accomplish this work, the resulting outputs will address the identification, justification, prioritization, classification and associated required documentation for the creation and maintenance
of individual alarms and associated support systems. • WG3—Basic Alarm Design: Covers the selection of alarm attributes such as types of alarms, deadbands and delay times. Because each control system has different capabilities with respect to alarms, the resulting implementation of this work may be specific to each control system. • WG4—Enhanced and Advanced Alarm Methods: Will provide guidance on additional logic, programming, or modeling used to modify alarm behaviour. The resulting tools to support advanced alarm methods will likely include dynamic alarming, state-based alarming, adaptive alarms, logic-based alarming, predictive alarming, as well as a number of approaches to logically implement designed suppression of redundant and condition-based alarms. • WG5—Alarm Monitoring, Assessment and Audit: Focuses on monitoring, assessment and audit for the continuous monitoring, periodic performance assessment and recurring audit of the alarm system to keep system and operator performance from deteriorating over time. Fortunately, many modern alarm systems contain the tools to assist in this activity already. • WG6—Alarm Design for Batch and Discrete Processes: Providing guidance on the application of alarm design of batch and discrete processes. Similar to ISA18, the ISA101 committee’s purpose and scope are to establish standards, recommended practices and/ or technical reports pertaining to human-machine interfaces in all manufacturing industry applications. The areas covered within ISA101’s work will include: menu hierarchies, screen navigation conventions, graphics and colour conventions, dynamic elements, alarming conventions, security methods and electronic signature attributes, interfaces with background programming and historical databases, popup conventions, help screens and methods used to work with alarms, program object interfaces and configuration interfaces to databases, servers and networks. As you can see from the above there is significant activity underway to ensure that we will be able to properly manage the plethora of data available in today’s control systems. The one thing that modern HMI and operator interfaces, both in the control room and on smaller devices, are doing is helping us to make informed decisions faster, less stressfully and with less chance for error. Ian Verhappen, P.Eng. is an ISA Fellow, ISA Certified Automation Professional (CAP), and a recognized authority on Foundation Fieldbus and industrial communications technologies. Verhappen leads global consultancy Industrial Automation Networks Inc. specializing in field level industrial communications, process analytics and heavy oil / oil sands automation. Feedback is always welcome via e-mail at iverhappen@gmail.com. HMI & Operator Interface Technology Handbook • MA 15
TECHNOLOGY HANDBOOK
HMI & Operator Interface
MY VIEW OF POINT OF VIEW BY JEREMY POLLARD
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utomationDirect’s “Point of View” (POV) Windowsbased software is a feature-rich industrial HMI with SCADA tendencies designed for machine control as well as plant floor enterprise. To be clear, AutomationDirect has licensed the core of a third-party technology and value-added to it to create POV. It is hardware dongle runtime protected. I thought that level of runtime protection was obsolete, but the cost — from US$495 — almost demands it. I installed the product on XP SP3 and it took me a few tries since certain Microsoft components needed to be installed first. Once completed, the install went without a hitch. I installed it standalone since POV comes as a client-server as well. The one thing that an HMI must do is communicate with various hardware platforms, which leads us into OPC drivers. POV supports AutomationDirect hardware, but also most of the mainstream PLCs and PACs with native drivers. Worksheets can be created for OPC components, however. The interface is slick — very Office 2013 with ribbons, menus and right click content, and a tabbed screen area. The help system is voluminous; however, I found it a bit rudimentary in places. Context-sensitive help is available and is accessed by pressing Shift-F1. It brings up a ‘?’ cursor to select what you need help with. I would have expected that POV would know when I pressed the keys what I needed help with. A bit unorthodox. POV does everything you would expect a SCADA system to do — it handles alarming, data logging and optimized communications due to native drivers. It has an interface with rich symbols and colour palettes, as well as security levels for user interaction. One very cool feature is you can program the application that you develop to start as a service, which means that when and if the computer the application is installed on goes through a power cycle, the application will run. If this is a server (POV supports remote web users and remote management), then the remote users will still have access to their data and interfaces. I created a basic project and screen. Since I have Rockwell hardware in my lab, I created the application around the PLC-5. There are a few things that are not intuitive. Most SCADA systems have scan classes for data logging and tags. This allows the developer to create timing demarcation points for different data types, such as temperature and pressure. Temperature can be updated every ‘x’ seconds, while pressure may need a faster update in the data logs. The default is 600 MSecs. You have to create a new communication worksheet to change the timing or manually edit the project file. Be aware of the web clients and mobile clients. Application scaling isn’t automatic. You don’t have to totally recreate the application for a web client, but the application doesn’t scale for mobile. It’s best to create a tabular application for mobile users. Creating a standalone application (HMI) is fairly straight16 MA • Technology Handbook HMI & Operator Interface
The POV development environment shows the tabbed interface and ribbon menu system
forward. I created a screen and a startup script to produce a “Hello” message, and populated the screen with some runtime symbols, such as motors and buttons. They were animated with the lab PLC-5. Tags were manually created, but you can import project tags using a CSV or text file import. The symbols are named oddly. For instance, arrow left is arrow6. Select the symbols using the symbol menu by clicking on the directory name under system symbols to access. The animation of the symbols is a little odd as well. POV is object-based and doesn’t assume anything, so if you want a symbol to rotate, you need to add that animation to the symbol directly. It’s easy to do, but part of the learning curve. Symbols can be created by merging symbols into a new one. Screen groups can also be created to minimize screen creation. Creating a menu screen and a user screen, then putting them together in a usable screen, allows the menu screen to be repurposed in a different group. If you use linked symbols, changing the master symbol changes all instances of the symbol. Use unlinked symbols if you want independency. AutomationDirect’s claim to fame is service and support. I had a conference call with the product team so I could ask some questions. Three of them spent an hour with me, which suggests to me that they are dedicated to helping. Deploying POV as an HMI or smaller-scale SCADA system can be recommended, but give yourself some time to go through the learning curve. While I found the product slightly unintuitive, once it is learned it can provide the user with a solid platform. Jeremy Pollard (jpollard@tsuonline.com) has been in the industrial automation industry for more than 25 years. He has worked as a systems integrator, consultant and educator.
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