How to Select Flat-Panel HMIs for Optimal Results in All Industrial Environments

Matching the performance of human-machine interface (HMI) flat-panel displays to requirements in industrial networking applications is complex. Network designers must consider numerous architectural, operational, and environmental factors.

Does the application need a web interface? Would an integrated programmable logic control (PLC) be beneficial? Is use in a harsh environment or outdoors anticipated? Those are among the simpler questions.

More complex decisions involve considerations such as environmental robustness versus touchscreen input performance. Input accuracy and responsiveness are important for complex control tasks, especially when workers may be wearing gloves.

Additional factors include integrated cybersecurity capabilities, mechanical ruggedness requirements, connectivity options, support for system integration, and more.

Regardless of the demands and complexity of the application, Pro-face by Schneider Electric supports the HMI needs of Industry 4.0 manufacturing, automation, and process control systems. The lineup begins with entry-level and basic models that can satisfy most industrial network application needs and extends to models rated for operation in extreme outdoor environments like oil rigs and chemical processing plants.

Entry-level and basics

HMIs in the Pro-face line are categorized into several performance tiers, beginning with the ET6000 Series, an entry-level model designed for simple, cost-effective machine visualization. Moving up to the next level are the ST6000 series basic models, such as the PFXST6500WADE, with more advanced visualization features, connectivity, and performance suited to more complex applications.

The ET6000 series is targeted at small machines, conveyor systems, building automation, and similar applications that require only basic control and monitoring. The ST6000 series offers more advanced built-in connectivity, such as an OPC UA server to support secure, standardized data flow.

The ST6000 series also supports Pro-face Connect, which provides secure, simple, cloud-based remote monitoring, diagnosis, and control of machinery from anywhere using PCs, tablets, or smartphones. While specific connectivity varies by model, the ET6000 series is generally more limited in the number and types of interfaces, offering only essential options such as Ethernet, serial ports, and USB.

The ST6000 HMIs offer a wider range of connectivity options and expandability, including support for various industrial protocols such as MQTT, multiple Ethernet interfaces, and expansion units, like video.

The ST6000 series includes five wide-screen and two traditional 4:3 aspect ratio models, while the ET6000 is available in four wide-screen models (Figure 1). Both series feature TFT color LCDs with 16 million colors and analog resistive touch panels.

Figure 1: There are four wide-screen models in the ET6000 family. (Image source: Schneider Electric)

Modular, advanced, and premium

The STM6000 is a modular basic HMI that offers the same advanced visualization features as the ST6000 series, but is designed for fast, tool-less, push-button installation into a standard 22 mm circular hole. It supports GP-Pro EX software for a smooth migration and integration with existing assets, and it can use Pro-face BLUE software for the latest features and capabilities.

For higher performance, Pro-face offers advanced and premium models. Advanced units like the PFXSP5400WAD offer significant additional features beyond basic models, primarily focusing on enhanced connectivity, performance, and flexibility to facilitate Industrial IoT (IIoT) solutions and secure remote access.

Premium models like the PFXSP5800WCD feature a higher-resolution screen with 16 million colors, compared with 262 thousand for advanced HMIs. The premium models also offer larger screens, up to 19”, compared with a maximum size of 12” for advanced models. Plus, the premium HMIs have front USB ports, a brightness sensor, and auto-scaling, features not offered with advanced units.

Bridging IT and OT systems

Providing an interface that bridges the chasm between operational technology (OT) systems on the factory floor and higher-level information technology (IT) enterprise systems, and the Cloud, can be an important consideration.

In addition to being powerful tools for data visualization, HMIs can gather real-time production data that can be stored in SQL databases or enterprise resource planning (ERP) systems, supporting data-driven decisions.

Pro-face Connect and Pro-face Remote software can provide secure remote access, allowing equipment operation and performance to be monitored from PCs, tablets, or smartphones. This can also improve flexibility and reduce maintenance response times.

Pro-face Blue Open Studio software supports over 250 communication drivers for PLCs and other devices. Depending on the model, Pro-face HMIs support over 1,200 devices, as well as industrial networking and IT protocols. That extensive communication and connectivity support enables Pro-face HMIs to link IT and OT networks from the factory floor to the Cloud (Figure 2).

Figure 2: Pro-face HMIs can provide an efficient and secure link between IT and OT networks. (Image source: Schneider Electric)

For example, the STM6000 Edge Box HMI can securely upload data to a variety of cloud services, such as Amazon Web Services (AWS) and Microsoft Azure, and integrate with platforms such as AVEVA Insight.

HMI + web connectivity

Pro-face STW6000 web HMIs include a browser that can be used as a web client to connect with programmable logic controllers (PLCs), motor drivers, and other devices. These HMIs can replace Basic HMIs on small machines and easily display HTML5 data.

They can also be a cost-effective secondary display for visualizing limited information for maintenance and diagnostics, directly from PLCs or from a main display if it has an embedded server (Figure 3).

Figure 3: STW6000 HMIs can be used as the primary display (left) or as secondary displays (right). (Image source: Schneider Electric)

HMI + PLC

Some applications can benefit from combining the functions of an HMI and a PLC into a single, compact unit. That’s where the STC6000 operator interface family comes in. This integrated solution can reduce component counts and simplify maintenance in small machines. It also eliminates the need for custom PLC controls and multiple software packages, further simplifying implementation and speeding deployment.

STC6000 units include serial, Ethernet, and USB interfaces. Connectivity can be extended with CANOpen and TM3 modules, and these controllers easily connect to third-party devices. They include integrated I/O that can support sensors, lamps, stack lights, or valves. With expansion options designed for motor control applications, these units are suited for industrial washing machines and packing machines (Figure 4).

Figure 4: STC6000 HMIs are highly flexible and suited for a variety of simple machine designs. (Image source: Schneider Electric)

Cybersecurity

Robust cybersecurity is an important consideration to ensure operational integrity. The latest Pro-face HMI lines, such as the ST6000, STW6000, STC6000, and SP5000 series featured in this article, are designed with extensive cybersecurity features to ensure safe OT/IT integration.

These Pro-face HMIs support several cybersecurity measures, including TLS encryption and secure remote access without complex firewall setups. They are compatible with external network-based intrusion prevention systems (IPSs), such as EdgeIPS.

As part of Schneider Electric, Pro-face employs a Secure Development Lifecycle (SDL) process, including threat modeling and penetration testing, to ensure its products meet industry standards such as IEC 62443.

Pro-face Connect provides an embedded, encrypted VPN solution for secure remote access, which can be managed with access levels and security certificates. Many Pro-face HMIs feature two Ethernet ports to allow for secure and straightforward network separation. For more details and deployment suggestions, designers can turn to the Pro-face HMI/IPC Cybersecurity Guide.

Glove mode and more

Several Pro-face HMIs include a “glove mode” that enables operation while the user is wearing gloves. Users can select glove mode in system settings, alongside other options such as standard mode (for bare-finger operation) and water detection mode, which disables touch input when liquids are on the screen to prevent unintended inputs.

Glove mode increases the touch sensitivity of a capacitive touchscreen. It enables the screen's software to recognize touch input from various glove types, such as nitrile, utility, or fleece gloves, which standard mode often fails to acknowledge.

It can be particularly useful in environments where users must wear gloves for safety or for comfort in cold weather (Figure 5). Glove mode is also included in the SP5000X Extreme series HMIs.

Figure 5: Glove mode enhances operator safety, efficiency, and comfort. (Image source: Schneider Electric)

Extreme performance

Applications like oil and gas drilling rigs and refineries, chemical plants, heavy-duty construction vehicles, parking lots, and gas stations can be exposed to extreme outdoor environments that demand rugged, high-brightness HMIs like the Pro-face SP5000X Extreme series.

For example, model PFXSP5690WAD is rated for operation from -30°C to +70°C, compared with 0°C to +55°C for most Pro-face HMIs. Some of the other extreme performance specifications of this series include:

• Brightness of 1,000 cd/m², and an antiglare screen for readability under direct sunlight
• Conform to IEC ingress protection levels IP66F and IP67F, where the “F” suffix indicates protection against oil or fuel splashes, and they are NEMA Type 4X/12/13 rated
• Enhanced shock and vibration resistance up to 2.7 times stronger than standard HMIs
• UV resistance cutoff of at least 99%, for high-level protection

Conclusion

There are Pro-face HMIs built for all types of Industry 4.0 operations. The offering ranges from entry-level units for simple machines to Extreme models for use in demanding applications and outdoor environments. They support the connectivity, reliability, software compatibility, and cybersecurity required for effective factory visualization.

Recommended reading:

1. Using Temperature Controllers and Micro PLCs to Speed Small-Scale Automation Projects
2. Use IO-Link for Increased Flexibility, Availability, and Efficiency in Industry 4.0 Factories
3. What are the Important Considerations when Assessing Cobot Safety?
4. Enhance Safety and Boost Availability in Industry 4.0 Factories
5. Using Light Curtains to Enhance Safety and Measure Objects