Human-Machine Interfaces (OIs) are increasingly evolving towards greater detail, efficiency, and functionality. Today's OI systems are more complex than ever before, offering higher precision monitoring and control of the processes they monitor. Their functionality ranges from a PLC terminal to a powerful processing platform. In its basic form, the interface can process data and send information to the operator in any way, from text messages to vivid graphics. Today, due to technological advancements, the scale of applications is expanding rapidly. While OIs are being developed to adapt to more needs, users continue to make increasing demands. A recent survey conducted by Reed Research among Control Engineering readers revealed that these respondents are well aware of the rapid growth and widespread application of these products. Of the 246 participants, almost all expected their demand for OI terminals to increase (46%) or remain flat (49%) over the next 12 months. Only 5% expected it to decrease. Regarding their perception of the growth rate of OI demand, nearly three-quarters expected the growth to be between 1% and 30%. Technological development and advancements in connectivity are the main reason for this application growth. The use of Ethernet, PC-based technologies in embedded configurations, and enhanced diagnostic capabilities have all driven rapid market growth. Clyde Thomas, Business Product Manager for Human Machine Interfaces at Eaton Electrical, believes, "In fact, the use of HMIs is being driven by more intelligent devices, including machine vision systems, sensors, drives, and power control devices that can communicate with PLCs." George Liao, Product Manager at Advantech, believes the widespread use of Ethernet provides more opportunities for OI applications. On the other end of the mature Ethernet network, OI systems include customized platforms, remote control/monitoring, and lower costs. He points out, "The market forecast for these major PC-based OI products is double-digit growth in 2005." Stable Platforms According to Reed's survey, the use of these devices will remain constant, close to last year's survey results. The survey shows that the largest user group of OI products, close to 49%, is in continuous and batch manufacturing industries. Of these, 16% is used for continuous manufacturing applications, a notable decrease of 3% compared to the previous year. Discrete manufacturing follows closely at 15%. Batch manufacturing, according to statistics, accounts for only 7% of applications. The remaining significant 13% is for important OI (Online Interface) terminal applications. Purchasing patterns also reflect this continuity. Over the past 5 years, 94% of respondents purchased the same or more PCs. Simultaneously, many purchased more or the same number of touchscreens (90%), enhanced color reception, and added graphics or networking systems. Looking ahead to the next 5 years, 90% of respondents said they plan to purchase more or at least the same number of PCs as before. 97% said they plan to add the same or more touchscreens, 97% will add the same or more color touchscreens, 96% will add the same or more levels of graphics rendering capabilities, and 96% will purchase more or at least the same number of OI devices with networking capabilities. The most interesting phenomenon emerged in the thin client and wireless OI sectors. In both cases, 90% or more respondents said they expect to purchase the same or more wireless or thin client operating interface devices over the next 5 years. 82% believed their purchases in these areas have remained the same or slightly increased over the past 5 years. Was it in the past? Or is it now? OI (Optical Interface) is a recognized diverse system, and its growth is faster than ever before. The respondents' wish list is shown in the figure; while most already have systems with multiple options, they still desire more features. Several key issues are: two-thirds of respondents own flat-panel displays, and over half want their next OI to also be a flat-panel display. The wish list also shows readability under certain contrast and brightness conditions and ambient light levels, with about half of the responses indicating a focus on these features. If the responses are accurate, at least some of these wishes are highly likely to be fulfilled. Paul Daugherty, OI product manager at GE Fanuc Automation, believes that more users will use OI products outdoors. He says, "In the future, we will see displays with high brightness and daylight readability, approaching NITS levels." In the area of ​​connected communications, a Reed research survey shows that one-third of users already have an open network, yet nearly half still desire this connectivity. Regarding software/operating systems, nearly two-thirds use Microsoft Windows NT, yet one-third hope to acquire it in their next purchase; nearly one-fifth of users use Windows CE, and 20% hope to use Windows CE in their next OI. Nearly 20% already use web browsers as basic software. NEMA ratings remain important. Half of the respondents have 4/4X and 12-rated systems, and more than a third plan to add this. Less than 20% of systems lack rating labels. Regarding these findings, Daugherty of GE Fanuc added, “Historically, the user interface was comprised of low-cost, low-functionality buttons and indicator lights, which are increasingly being replaced by higher-cost, high-functionality computer-based products. OI users want products with higher functionality, lower prices, and less system complexity than computers. This will become possible with the advent of Windows CE-based OI products.” The issue of various certifications remains . The choice of various certifications and networks still carries weight, and the survey shows that assurance of application in hazardous environments is a concern. For Class I, Div. 1 certification, 16% of respondents indicated they already have it, but nearly 40% hope to have it in the future. Meanwhile, for Class II, Div. 2 certification, 18% of respondents already have it, and nearly 30% hope their systems will have it in the future. UL certification is commonplace, with 85% of respondents saying they already have it in their systems, and 74% hoping to have it in future purchases. CE Mark and CSA certifications didn't garner as much attention. Approximately 43% have CE Mark in their current systems, while only 40% are looking for it in their future systems. Meanwhile, 37% have systems with CSA directives, but only 36% expect this certification in their next OI. In the networking arena, it overwhelmingly became the most favored option among respondents. Nearly 80% of respondents said they use Ethernet TCP/IP and intend to continue using it in the next 12 months. Other options are also available, such as RS-232 (76%), RS-485 (71%), and 4-20 mA (63%). Other accepted networks include FOUNDATION Fieldbus, Profibus, ControlNet, DeviceNet, HART, and Modbus. More than half (53%) use or plan to use DeviceNet, 46% use or plan to use ControlNet, 23% are choosing Fieldbus; 36% use HART, 29% use Profibus-DP; and nearly 40% use or plan to use Modbus or Modbus TCP/IP. One-third of respondents currently use private networks or plan to continue using them in the next 12 months. The Future of Bridges What's at the forefront of the OI market? It all points to bigger, better, and more. Clyde Thomas of Eaton Electric says, "OI vendors need greater flexibility in supporting communication with third-party devices, which will mean faster adoption of more open communication standards, such as OPC. Balancing cost, performance, and ease of use also requires more embedded technology. There will also be some potential benefits for users, but understanding the shortcomings and issues of these new OI platforms requires more training and expertise." Rick Barnich, VP of Ann Arbor Technologies, believes future technology will focus on server-based technology and the development of larger displays. His company, he noted, will offer updated systems in a smaller, embedded tablet architecture while maintaining standard industrial computer settings. Barnich said, “We’re looking to move into more central server applications where licensing, maintenance, and security costs are lower. To fit this architecture and keep costs under control, the operator interface is now an embedded Linux or embedded XP client. Also, the inherent size and complexity of these applications are driving up the size of general operator interface displays…” Regardless, the importance of operator interfaces for automation is undeniable. Various systems are demanding greater and more extensive automation capabilities. Whether it can perform complex controls, has wireless networking, or larger, better displays will be the questions facing the future of OI. Operator Interface Products Advantech Automation’s TPC-1260 touchscreen tablet computer offers a powerful, cold-running processor in a fanless, elongated design. The device features a 12.1-in. SVGA TFT LCD, a durable touchscreen, free-axis storage, and a Transmeta Crusoe 5400 processor. It offers 128MB of onboard DRAM and a compact flash drive. The component supports Windows XP/CE and features a NEMA 4/IPC 65 front panel AL-Mg cavity, making it suitable for harsh environments. For applications where axial degrees of freedom are not critical, a narrower form factor can be used. The Ann Arbor Technology webLink21 high-performance industrial computer integrates a large UXGA 21-in. display . An analog durable touchscreen with a NEMA 4 protection rating and an aluminum front bevel is standard. Key features include a 1.7 GHz Pentium 4 processor and DDR RAM (upgradable to 1 GB), an onboard 100/10 BaseT Ethernet port, CD-ROM, 4 USB ports, and an additional 6 open PCI slots. Enhanced RAM, a DVD drive, additional USB ports, and a NEMA 4X stainless steel bevel are available as options. The GE Fanuc QuickPanel series of touchscreens with Cimplicity Machine Editor software and Microsoft Windows CE operating system offers comprehensive compatibility . This single-platform compatibility provides enhanced productivity and cost-effectiveness. The touchscreen offers flexible, scalable performance on a hardware platform integrated with automation software. The Cimplicity Machine Editor—an open, integrated software package suitable for machine-level programming, monitoring, data capture, and fault detection—drives application software development. Transparent access from Omron Electronics' advanced operating interface allows access to information from the PLC to three remote networks on a single screen. Information can be uploaded from an Ethernet network, a ControllerLink network (Omron's proprietary network), and simultaneously to two serial ports. The HMI features a unique 4-channel video input module to display camera images from vision inspection sensors. Connectivity provides users with extensive network access to data, and ladder monitoring tools can monitor PLC ladder programs from a single system menu without requiring a laptop or PC. The NS protection rating is NEMA 4. AutomationDirect's Extended Touch Panels : AutomationDirect's Extended Series of Touch Panels includes 8, 10, and 15-in. elongated devices. These elongated panels utilize FDA-compliant molding materials and touch covers, including 1/4-in models. FDA-compliant O-rings are included. Typical modules feature built-in data path additional accept capabilities and Ethernet select cards. 10- and 15-in. panels offer Modbus Plus, DeviceNet, Profibus, or Ethernet I/P accept capabilities. Starting price is $419, available in color or monochrome. Xycom Automation's GP2x01 Series of Programmable Touch Interfaces: The GP2x01 series of programmable touch interfaces can operate in most environments. This device features an aluminum housing construction, NEMA 4x protection, Class 1, Div 2 hazardous area certification, and a compact flashcard for data logging and direct access to configuration software. This device supports a wide range of popular serial communication drivers, and optional communication expansion modules provide network interfaces for connection to DeviceNet, Profibus, Modbus Plus, AB Data Path Plus, AB Remote I/O, and additional standard RS-232/RS-485 networks. The text-based HMI from Square D/Schneider Electric, the Telemecanique Magelis XBT-N, is designed for simple and repeatable operation. With NEMA 4X protection for outdoor use and UL Class 1, Div. 2 hazardous location protection, this linear, compact text-based HMI is easy to install and program. Four specifications offer high functionality and a uniquely fast response time. The response time for operator actions from the keyboard or requests from the PLC is less than 30ms. The operator panel can be customized using software setting keys, and open standards ensure compatibility with Schneider Electric and other third-party components.