How Controller & HMI Integration Enhances Manufacturing

By Susan Burtch, Lead Commercial Portfolio Manager, Visualization Software, Rockwell Automation

The increased use of digital transformation and automation has created a growing need for seamless integration of human-machine interface (HMI) software and controllers in manufacturing. Let’s explore the reasons, challenges, system considerations and benefits associated with this integration for various stakeholder groups.

The Imperative for Integration

Manufacturers continually need to streamline operations, improve efficiency, reduce production costs and maximize resources and capacity. Technological advances have enabled a tighter integration of the HMI and controller, with the controller providing manufacturers with a single source of data truth.

This integration extends to both HMI and controller applications. Consequently, companies are merging engineering teams and consolidating resources, becaise there’s no longer a need for separate application development.

Previously, application development for the HMI and controller involved importing tags, defining tag metadata, maintaining tag references throughout the HMI, and mapping the data tags to the controller. This approach was labor-intensive and exposed systems to potential errors.

Integration eliminates duplication, minimizes errors and streamlines system design and programming, resulting in a simplified process and improved workflow that enhances business continuity and operational smoothness by unifying efforts.

In addition, alarm management plays a vital role in any control system. Integrated systems simplify alarm setup and maintenance in one location, reducing effort and risk. With alarms integrated into the controller, data remains steady even during communications loss, because integrated systems cache and recover alarms.

Challenges Integrating HMIs and Controllers

Technological advancements present their fair share of challenges, and the integration of HMIs and controllers within manufacturing is no exception.

One common challenge involves dealing with multiple vendor sources. Typically, manufacturing systems comprise equipment and software from various vendors with different sensors, controllers and HMIs, making it complex and challenging to achieve tight integration across several platforms.

Effective integration relies on the HMI and controller's ability to communicate using the same protocol. Compatibility issues might arise when older controllers lack support for modern protocols, presenting a significant challenge in bridging this technological generation gap.

Data mapping represents another obstacle, because the HMI must map its data tags to the controller's data points. This can be a complex process, particularly if the controller has numerous data points.

Considerations for Integrating HMIs & Controllers

An important consideration lies in the user experience. The HMI must prioritize operator-friendliness, featuring well-designed screens, easily accessible controls, and clear and concise presentation of information.

Also, localization for different languages and cultures is crucial. This involves translating the text and graphics on the HMI into the appropriate language and ensuring the HMI can display different measurement units and date formats.

A seamless and intuitive user interface is essential for optimizing operational efficiency, and wherever possible, taking advantage of controller integration to collect and display data to the operator.

Security is crucial in HMI integration. The HMI should incorporate user authentication and authorization features. Integrated security in a system, where user login credentials are used for both HMI access and controller maintenance, is key. Regular updates and prompt application of security patches are imperative.

Streamlining the Deployment Process

When manufacturers integrate the HMI with the controller in a system, it’s crucial to understand how these components communicate and collaborate effectively. This involves asking critical questions, such as:

• What will the operational workflow involve when using the integrated system?
• What key considerations should inform the system's design?
• How should alarms be configured to optimize functionality?
• How should data tags be established within the system? Should this initiation occur within the controller and then be imported into the HMI?
• What information can be seamlessly shared or repurposed between the controller and the HMI to promote data cohesion?
• To what extent can these processes be efficiently automated?

When selecting an HMI for controller integration, it’s essential to choose one that aligns with the controllers' requirements. Ideally, the HMI and controllers should come from the same vendor to reduce the complexity of supporting diverse platforms and ensure harmonious operation. However, if a single-vendor option isn’t feasible, selecting a technology-agnostic HMI allows for communication with any OEM product in the manufacturing system.

The HMI must also comprehend the functioning of each OEM product, discern the communication protocols in use and advise on the need for supplementary drivers. If a specific driver for other equipment in the system isn’t available, the HMI should be able to establish communication via OPC UA, an open-source, cross-platform standard that simplifies data exchange from sensors to cloud applications.

By addressing these critical considerations, manufacturers can facilitate the seamless integration of HMIs and controllers in a manner that aligns with their unique operational needs and preferences.

Realizing Benefits

After integrating the HMI and controller, manufacturers can unlock a range of benefits that cater to various stakeholders involved in the process.