Visualisation for visionaries with a cloud-based HMI platform

IN THE current digital era, organisations must leverage new technologies to drive innovation, streamline operations, and enhance business agility. A key element in this technological landscape is the human-machine interface (HMI), designed to provide an intuitive and accessible interface for operators. Effective HMI systems can enhance flexibility, boost productivity, and simplify troubleshooting.

Real-time decision-making begins with data visualisation built on interoperability and openness. This approach ensures that HMIs are user-friendly, allowing operators to work efficiently with interfaces automatically configured to their preferred language, regional settings, and formats. HMI designers require tools that facilitate rapid solution creation and offer advanced ways to visualise and utilise data from the plant floor to the entire enterprise.

Efficient manufacturing demands exceptional, user-friendly, contextualised data with secure, 24/7 access worldwide. The cloud-based FactoryTalk Optix visualisation platform exemplifies this need with its open and extensible design. It simplifies the design process, fosters collaboration, and provides unmatched flexibility to customise applications to meet operator requirements.

Technological advancements have significantly influenced the evolution of HMIs, resulting in more user-friendly touch-based interfaces and improved data access. Recent developments include the integration of HMIs with automation and the Industrial Internet of Things (IIoT), enabling enhanced machine-to-machine communication, remote monitoring, and overall control.

The evolution and future of HMI

Future HMIs will likely incorporate Artificial Intelligence (AI) and Machine Learning (ML), allowing smart devices and applications to anticipate user needs, adapt to preferences, and enhance user experience through data analysis. With the growth of IIOT, HMIs will play a crucial role in managing and controlling interconnected devices, offering a unified and cohesive user experience.

As technology and automation drive the next generation of manufacturing, all roles will benefit from these advancements. Real-time decision-making is facilitated by visualisation built on interoperability and openness, ensuring operators can work efficiently with minimal training. FactoryTalk Optix allows HMI developers to create an intuitive user experience, reducing the need for extensive training.

Modern HMI tools improve efficiency by providing comprehensive project visibility within a collaborative design environment. This visibility helps track progress, identify responsible parties, and understand the rationale behind changes. New HMI software tools offer timely and relevant information, enabling quick and informed decision-making. Web-based HMI tools empower teams to design, deploy, and update applications remotely, seamlessly integrating changes within the production environment.

The story behind the FactoryTalk Optix platform picked up pace when Rockwell Automation acquired ASEM, an Italian leader in digital automation technologies, back in 2020. ASEM's portfolio included robust hardware, cutting-edge designs, and two innovative software platforms: a remote access product and a highly flexible HMI product, later known as Optix.

Optix stands out for its exceptional openness. It is capable of interfacing with competitive network protocols and aligning with Industry 4.0 standards. While discussions around Industry 4.0 often emphasise openness, Optix embodies this principle deeply within its core architecture.

Rockwell Automation is focused on integrating efficient workflows directly into the product rather than offering them as add-ons. Optix supports multiple users and includes tools for comparing changes, managing versions, and maintaining rollback control. FactoryTalk Vault, Rockwell's backend service, complements these processes. However, Optix's open nature allows it to integrate seamlessly with other repositories like Microsoft's GitHub, supporting Git-enabled workflows.

Library management is another area in which Optix excels. It provides version control for libraries, which is crucial for OEMs managing multiple machines and corporate standards. Changes in library icons, such as a login icon update, are automatically notified to users, similar to mobile app updates.

A more intuitive HMI

Case Packing Systems (CPS) has become one of the pioneering companies in the Benelux region to implement the FactoryTalk Optix software platform, utilising the HMI and data-visualisation software to optimise the design, testing, and development of programming for its modular case-packing technologies. The new machine platform aims to enhance export potential by leveraging a comprehensive Rockwell Automation hardware architecture, mainly targeting the North American market.

The integrated architecture was developed with assistance from Routeco Netherlands, a member of the Rockwell Automation PartnerNetwork. Routeco Netherlands passed the configuration to VerAutomation, an industrial automation specialist and part of VINCI Energies. VerAutomation developed the PLC code using Studio 5000 Logix Designer software and the control application programming interface (API) with the FactoryTalk Optix platform. The PLC code adheres to ISA-88 standards, and the use of FactoryTalk Optix ensures the software solution is future-proof.

CPS constructs its machines using modular components, allowing each customer application to have a unique combination of technologies requiring specific HMI programming and testing. The FactoryTalk Optix software enables CPS to reuse software modules and add-on instructions, significantly reducing development lead times. This capability also helps CPS achieve an automation solution that is widely accepted in the North American market.

When powered on, the HMI detects the modules in the programmable logic controller and generates the HMI application, with 80% of the program generated during startup. This results in quicker development and faster launch possibilities. Additionally, CPS's machines have become smarter, with more features and a substantial increase in operational data generation compared to previous solutions. End-user operators benefit from a clearer and more intuitive HMI interface, enhancing usability and efficiency.

Impact across development phases

FactoryTalk Optix benefits each phase of machine development, from design through deployment, graphics, and extensibility. Initially, it offers designers considerable flexibility in creating and testing HMI projects via the cloud or desktop software. This allows for modifications from any location, incorporating version management to track changes. Integrated with cloud storage and version control through GitHub or FactoryTalk Vault, designers can dynamically build projects at runtime.

During the deployment phase, it enables the creation of applications that can be deployed across various devices, supporting ARM/x86 systems, Windows, Linux, and HTML5 browsers. This flexibility ensures no dependency on specific display devices. Applications can be deployed to edge or standard industrial PCs, OptixPanel terminals, or web clients, allowing local and remote users to access the application independently.

Graphics provide tools for designing responsive and modern HMI interfaces compatible with any device. All graphics are scalable SVGs, allowing consistent display across different screen sizes. Style sheets enable property specification for all graphics objects, supporting runtime changes such as switching between light and dark modes. Multi-language support adjusts the language, units, international settings, and date formats.

Finally, it is designed for extensive connectivity and customisation in the extensibility phase. It supports a range of protocols, including MQTT, HTTPS, native OPC UA, and third-party drivers. With built-in OPC UA support, the platform facilitates object-oriented design, machine-to-machine communication, and interfacing with MES, ERP, and cloud systems. All project resources are structured as OPC UA objects, enabling automatic interfacing with compatible systems.

Ultimately, Optix enhances engineering efficiency and facilitates remote access. Users can invite others into remote access scenarios, increasing transparency. OEMs can use Optix's remote access solution to ask customers to examine their machines, making factory acceptance testing more convenient. Engineers no longer need to travel; a simple double-click grants them access to FactoryTalk Hub, allowing them to interact with equipment as if on-site.

The integration of FactoryTalk Optix Studio with the remote access solution enables users to browse and manage their equipment globally, streamlining operations and enhancing productivity.

Mauro Galano is product manager EMEA visualisation at Rockwell Automation

www.rockwellautomation.com