Due to the increasing level of automation and the constantly growing capabilities of robots, less and less human support is required in many factories. However, humans are still indispensable for the monitoring, control and maintenance of machines and robots in the smart factory. Another effect that goes hand in hand with increasing automation is that more and more data is being generated. These mountains of data need to be analyzed in depth and converted into useful information that is valuable for the company's success. In order to make optimal use of this data and analysis, it must be available and visualized - often in real time - both on the factory floor and in the control room. People must be able to access all relevant data, information and processes. HMI devices such as monitors or panel PCs are the 'window to the process' and enable it to be monitored, coordinated and optimized. A wide range of requirements in terms of display size, display quality, robustness and integrability are demanded. Modern, intelligent HMIs are integrated into the automated production processes of the smart factory and provide relevant information at the right time and in the right place, thus enabling efficient decision-making.

Traffic light systems show status

In many cases, traffic light systems (tower lights) above the machines characterize the image of production facilities. They indicate the status of machines according to the traffic light principle: green - ok, yellow - requires adjustment or correction, red - means the machine has stopped.

Behind the simple color display is the Andon principle derived from Japanese production teachings. The idea behind it: To quickly inform employees in production about the location and type of problem in order to enable them to intervene and thus avoid production downtime. However, a simple traffic light is not enough with today's highly complex machines and processes - further information should be provided in addition to the machine status in traffic light colors. Decisions can then be made on this basis. Andon boards are therefore often used in addition to the traffic light systems. If these are implemented as real displays, they have the decisive advantage over pure traffic light systems that they can display further detailed information in addition to the traffic light colors, such as information on the type and location of the fault.

XXL monitors for Andon boards

Andon boards can also increase efficiency during normal operation. For example, extracts from existing SCADA or MES solutions can be displayed or other information, such as an indication of upcoming maintenance work or safety instructions.

However, the area that can be displayed visually on a conventional industrial screen is usually not sufficient. A clear display, especially over long distances, is only possible with large-format industrial monitors and panel PCs. They can be positioned in a central location and thus be viewed from each individual section of a production line. Thanks to the screen size and high resolution, all information is clear and easy to read. Skilled workers can also quickly recognize the status in upstream and downstream sections, as well as where a problem is occurring that may pose a threat to their work area.

Complex processes can also be displayed on the large-format monitors in such a way that many details can be shown even at the top visualization level. Their size and high resolution make this clear display method possible in the first place. The next step is to use the touchscreen to navigate to deeper process levels.

Last but not least, large monitors support the trend towards a paperless factory. Even complex design drawings can be clearly displayed on an XXL monitor. The same applies to information on the configuration and assembly of products. More information can be displayed on the large-format monitor, making it easier to navigate through documents and increase concentration on the tasks to be carried out. All data can be retrieved from a central data source. This ensures that they are consistent and up to date. Outdated paper templates are a thing of the past.

The large-format monitors or panel PCs, such as those offered by Kontron with the FlatView XXL or FlatClient XXL with a screen diagonal of up to 75 inches and up to an ultra HD resolution (4k), are available with various mounting options. Depending on requirements, the monitors and panel PCs can be attached to walls or stands using VESA mounts or even suspended from the hall ceiling using ring eyelets. Kontron currently offers an ECO version with Intel Atom Quad Core processors or a Pro version with Intel Core i5 processors for the panel PCs in the Flat Client series with formats from 10.4 to 23.8 inches or the Flat Client XXL series up to 75 inches.

Visualization up to 100 meters distance

WideLink is a transmission method according to IEEE1911 that is independent of the operating system and is used to implement data communication between the remote visualization system and the control computer via an Ethernet cable. Visualization units can be operated up to 100 m away from the control computer using this technology.

© Kontron

With Kontron's WideLink technology, screens can even be positioned up to 100 meters away from the signal source. The transmission method includes the digital signals for the screen, the feedback from the touch interface as well as USB and audio signals. WideLink tunnels these signals through a standard Ethernet cable and makes them available at the end device without any loss of time or quality. No CPU or memory is required in the control computer for transmission, and no operating system or additional software is needed. The image data is transmitted loss-free and in a resolution of up to Full HD. WideLink technology is available both integrated in a powerful embedded box PC and via a WideLink transceiver, which connects any PC to the corresponding monitor, regardless of the manufacturer. The Kontron FusionView industrial monitor with integrated WideLink interface is suitable as a decentralized visualization unit.

Computing power directly on the monitor

Panel PCs are always necessary when 'intelligence' is required directly on the monitor. Depending on the application, differently powerful systems are required, which must also be integrated into the local infrastructure. Resistance to dirt, water, vibrations and other environmental influences is not the only thing that counts for industrial-grade HMIs. The panel PC must also fit seamlessly into an existing OT and IT environment. It is also important that it meets the current standards, particularly in terms of networking and security. Networking can, for example, be wired via Gigabit Ethernet connections or via WLAN. Kontron offers systems with internal WLAN antennas that are protected from environmental influences but also offer the best reception quality.

The FusionView industrial monitors are based on a frameless design and have a scratch-resistant and anti-reflective front glass. They are optionally available with LED alarm bar.

© Kontron

If control via the industrial monitors is required in addition to pure display, touchscreens are used that are either touch-sensitive or pressure-sensitive. The variant with pressure-sensitive screens (resistive touch) is suitable for tasks that do not allow sensitive control by touching with the fingers due to the ambient conditions. For example, in systems where employees have to wear thick gloves or heavily soiled hands do not allow reliable control on the touchscreen.

The touch-sensitive screen (capacitive touch), on the other hand, accepts all inputs - just like the surface of a smartphone or tablet. Actions can simply be triggered with the fingers by swiping and touching without applying pressure. A so-called projected capacitive touch display (PCAP) is also characterized by an extremely resistant glass surface. The sensor film is applied to the inside of the glass. This design makes these touch-sensitive screens very scratch-resistant and durable. Another example are so-called IR touch displays. Their functionality is based on the light barrier principle, which is used in XXL monitors and XXL panel PCs, for example.

Kontron ensures investment protection through the long-term availability and updatability of all components, which are based on current processor and other industry standards.

Protection in an industrial environment

Monitors for industrial environments face particular challenges: they must be permanently resistant to strong shocks or vibrations. In addition, protection against the ingress of dust or, under certain circumstances, splash water must be guaranteed. Depending on the requirements, Kontron offers systems that are resistant to light environmental influences or completely sealed devices with protective glass that are sealed against dust and strong water jets and can even withstand high-pressure cleaners - up to protection class IP69. In addition, it is still necessary for the display to be easy to read in all lighting conditions - regardless of the amount of daylight - (e.g. by means of a matt, anti-reflective surface) and also shatter-proof - especially for applications in the food or pharmaceutical industry.

In general, HMIs must be designed to be as fail-safe and maintenance-free as possible. This includes, for example, not equipping monitors and panel PCs with fans, as moving parts are subject to wear and tear and are therefore usually one of the weak points. Panel PCs therefore rely on processors with the best performance-per-watt ratio so that they can also be operated without fans.

Kontron already offers a large number of its systems in flexible and powerful standard configurations, but also allows further customization to given requirements by means of a sophisticated modular design with defined internal interfaces. In this way, individual devices can be configured from a basic product. The advantages are obvious: solutions are developed on the basis of standard devices according to the desired requirements. The standard devices and the standard components they contain are already in series production and have a correspondingly high level of reliability and maturity. This forms a solid foundation for individual solutions.

Author:
Günter Deisenhofer is Product Manager for HMIs at Kontron.