4 Industrial HMI Trends Shaping the Future of OEM Design
- 2 days ago
- 5 min read
Industrial human-machine interfaces (HMIs) are changing. As manufacturing equipment becomes more sophisticated, the touchscreen is evolving from a simple control panel into an increasingly important interface for machine data, visual inspection, diagnostics, operator control and system status. For OEMs designing the next generation of industrial equipment, that evolution has important implications.
Touchscreens need to display more information, operate reliably in demanding environments and remain supportable throughout equipment lifecycles that may extend for many years. From machine vision and larger displays to rugged touch performance and long-term component availability, here are four industrial HMI trends OEMs should consider when designing their next system.
1. Machine Vision Is Making Industrial HMIs More Visual
Machine vision has become an important part of automated manufacturing, inspection and quality control. Modern vision systems can use cameras and image-processing software to inspect components, identify defects, verify positioning, take measurements and monitor production processes. But detecting a problem is only part of the equation. Operators still need an effective way to understand what the system has found. That is changing the role of the HMI.
Instead of simply displaying a PASS or FAIL message, an industrial touchscreen may need to present:
Camera or inspection images
Highlighted defects
Measurement results
Production statistics
Machine status
Alarms and warnings
Operator controls
Diagnostic information
This creates new requirements for the display itself. Resolution, screen size, optical clarity, viewing angle and responsive touch performance can become increasingly important when operators are evaluating detailed visual information. For OEMs developing machine vision equipment, the HMI should therefore be considered part of the complete operator workflow, not simply a display added at the end of the machine design.
2. Larger Industrial Touchscreens Are Handling More Information
As industrial systems collect and display more information, the traditional small control screen may not provide enough room to present it effectively. Today's operator may need to see machine controls, production information, alarms, diagnostics, images, graphs and equipment status simultaneously. Larger industrial touchscreens provide designers with additional screen real estate to organize that information. High-resolution displays can also allow more information to be presented without sacrificing clarity.
But bigger does not automatically mean better. A large touchscreen overloaded with controls and data can make an HMI more difficult to use. Operators need to be able to recognize important information quickly and understand what action is required. OEMs should therefore consider both screen size and information hierarchy when designing an industrial HMI.
Questions to consider include:
How much information does the operator actually need at one time?
Will images, diagrams or machine vision results be displayed?
How far will the operator typically stand from the screen?
Will multiple machine functions share one interface?
How large do touch targets need to be for gloved operation?
Will the display be viewed from different positions or angles?
Selecting the touchscreen early in the design process allows the physical display, interface layout and operator workflow to be developed together.
3. Reliable Industrial Touchscreens Matter More as Touch Takes Over
Moving controls onto a touchscreen can simplify an equipment interface and give designers far greater flexibility than a panel filled with dedicated buttons and switches. It also makes reliable touchscreen operation increasingly important. An industrial touchscreen may encounter conditions that a consumer touchscreen never will.
Depending on the application, that can include:
Water, rain or washdowns
Thick work gloves
Electrical noise and EMI
Extreme temperatures
Dirt, grease and other contaminants
Vibration
Thick protective cover glass
Nearby motors, power supplies or RF devices
For projected capacitive (PCAP) technology, reliable performance in these conditions depends on more than the touch sensor alone. The touchscreen sensor, controller, firmware, cover glass, LCD, bonding, enclosure and surrounding electronics can all influence final system performance.
Even physical integration decisions can affect performance. Screen orientation, mounting angle, controller placement, water drainage, power quality and proximity to motors, antennas and other electronic devices should be considered during system design.
This is why touchscreen integration and testing should occur early in the OEM design process. UICO's duraTOUCH® PCAP technology is engineered for demanding industrial and outdoor environments, including applications involving water, gloves, electrical noise and extreme operating conditions. Controller programming and firmware can also be tuned for the requirements of a particular application. As more machine functionality moves onto the touchscreen, designing for reliable touch performance becomes part of designing a reliable machine.
4. Industrial Equipment Outlives Consumer Technology
One of the biggest differences between industrial and consumer electronics is the expected product lifecycle. Industrial machinery, medical equipment, transportation systems and other OEM products may remain in production or service for 10, 15 or even 20 years. The electronic components inside them do not necessarily follow the same timeline. LCD panels can reach end-of-life. Controllers change. Components become unavailable. New generations of displays can have different dimensions, interfaces, mounting locations or optical characteristics.
For an OEM, a seemingly simple display change can therefore trigger an expensive redesign.
Changing an LCD may affect:
Mechanical dimensions and mounting
Display resolution
Video interfaces
Touchscreen dimensions
Cover glass
Optical bonding
Controller compatibility
Firmware
Enclosure design
Regulatory testing
OEMs should consider touchscreen and display lifecycle requirements during initial product development rather than waiting until an end-of-life notice arrives. Finding another display with approximately the same screen size is not necessarily enough. Mechanical dimensions, mounting locations, viewing area, brightness, electrical interfaces, optical performance and long-term availability can all affect whether a replacement can be integrated without substantial redesign. Planning ahead can help OEMs protect existing product designs, reduce future engineering work and extend the useful life of equipment already proven in the field. A touchscreen solution should not only work when the first machine ships. It should support the long-term requirements of the OEM product it becomes part of. UICO also offers drop in replacements for end of life touch screens.
Designing the Future of Industrial HMIs
Machine vision, larger displays and increasingly sophisticated industrial equipment are changing what operators expect from an HMI. At the same time, the fundamentals of industrial design have not changed. The interface still needs to work reliably every day, in the environment where the equipment actually operates, and it needs to remain supportable throughout the life of the product.
For OEMs, that means touchscreen selection should be considered early in system design rather than treated as a final component choice.
UICO engineers and integrates rugged projected capacitive touchscreen solutions for industrial, machine vision, outdoor and other demanding applications. From touchscreen and LCD selection to cover glass, optical bonding, controller tuning and system integration, UICO works with OEM engineering teams to develop touch interfaces designed for real-world operating requirements and long-term product support.
Frequently Asked Questions
What is an industrial HMI?
An industrial human-machine interface (HMI) allows an operator to view information and interact with a machine or industrial system. Modern HMIs can combine machine controls, status information, alarms, diagnostics, images and production data on a touchscreen interface.
Why are larger touchscreens being used in industrial equipment?
Larger displays provide more space for machine controls, production data, diagnostic information, images, graphs and other information. They can be especially useful for machine vision and complex equipment where operators need to monitor several types of information simultaneously.
How does machine vision affect HMI design?
Machine vision systems can generate images, inspection results, measurements and defect information that operators need to review. This can increase the importance of screen size, resolution, optical clarity and an interface layout that allows operators to understand results quickly.
Why is PCAP technology used for industrial HMIs?
Projected capacitive touchscreens provide responsive, accurate touch performance and support modern multi-touch interfaces. Properly engineered PCAP systems can also be optimized for demanding conditions such as water, gloves, electrical noise and extreme temperatures.
Why should OEMs consider touchscreen lifecycle during product design?
Industrial equipment can remain in production or service much longer than individual electronic components. Planning for LCD availability, controller compatibility, mechanical fit and potential replacement components can help reduce the risk of costly redesigns later.
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