Integrated HMI/PLC stands for Human Machine Interface and an Integrated HMI/PLC is just that, it is the interface between the user and the machine. An Integrated HMI/PLC is considered an interface; a very broad term that can include: Mp3 players, integrated computers, household appliances, and office equipment. But an Integrated HMI/PLC is much more specific to manufacturing and process control systems. An Integrated HMI/PLC provides a visual representation of your control system and provides real time data acquisition. An Integrated HMI/PLC can increase productivity by having a centralized control center that can be made extremely user-friendly.

There are three basic types of HMIs: the pushbutton replacer, the data handler and the overseer. Before the Integrated HMI/PLC came into existence, there could be hundreds of pushbuttons and LEDs all performing different operations. The pushbutton replacer Integrated HMI/PLC has eliminated the need for so many buttons, and has centralized all the functions of each button into one location. The data handler is perfect for when you need constant feedback from your system or printouts of the production reports. With the data handler you must ensure your Integrated HMI/PLC screen is big enough for such things: graphs, visual representations and production summaries. The data handler includes such functions as recipes, data trending, data logging and alarm handling/logging. Finally anytime your application involves SCADA or MES, an overseer Integrated HMI/PLC is extremely beneficial. The overseer Integrated HMI/PLC will most likely need to run windows and have several Ethernet ports.

The greatest advantage of an Integrated HMI/PLC is that it is very user-friendly because of the graphical interface. The graphical interface contains color coding that allows for easy identification (red for trouble). Pictures and icons allow for fast recognition, easing the problems of illiteracy. Integrated HMI/PLCcan reduce the cost of product manufacturing and potentially increase profit margins by both improving brand and lowering production costs. Integrated HMI/PLCdevices are innovative and capable of higher capacity and more interactive elaborate functions. Some technological advantages Integrated HMI/PLCoffers are: converting hardware to software, eliminating the need for mouse and keyboard, and allowing kinesthetic computer/human interaction.

The Integrated HMI/PLC is used throughout numerous industries including metals manufacturing, vending machines, food and beverage, pharmaceuticals and utilities, just to name a few. In metals manufacturing, an Integrated HMI/PLC has control of how the metal is cut and folded and how fast to do so. An Integrated HMI offers improved stock control and replenishment so the fewer journeys are required out to the vending machines. The Integrated HMI/PLC is used in bottling processes to control all aspects of the manufacturing line such as; speed, efficiency, error detection and error correction. Utilities uses the Integrated HMI/PLC to monitor water distribution and wastewater treatment.

The operating environment should always be accounted for because if you are in a warehouse that has excessive noise or vibration you might decide on a heavy duty integrated HMI/PLC. If you are in the food processing industry or somewhere that might need to be washed down every day you will have to think about a water-protected integrated HMI/PLC. You may also want to consider temperature as a factor in your selection process because if you were to be in a steel plant and next to a furnace you would want something that can withstand those temperatures.

An Integrated HMI/PLC is a big purchase so it is necessary to know exactly what it will be used for. An Integrated HMI/PLC is used for three primary roles including a pushbutton replacer, data handler, and overseer. The pushbutton replacer takes the place of LEDs, On/ Off buttons, switches or any mechanical device that has some control over the unit. The elimination of these mechanical devices is possible because the Integrated HMI/PLC can provide a visual representation of all these devices on its LCD screen while performing all the same functions. The Data Handler is used for applications that require constant feedback and monitoring, oftentimes these Data Handlers come equipped with large capacity memories. The last of the three types is referred to as the overseer because it works with SCADA and MES which are centralized systems which monitor and control entire sites or complexes of large systems spread out over large areas. An Integrated HMI/PLC is usually linked to the SCADA system's databases and software programs, to provide trending, diagnostic data, and management information.

The convenience that comes with an Integrated HMI/PLC is priceless; you will find that once you have digitized your system the functionality you will get out of your Integrated HMI/PLC is unbeatable. Integrated HMI/PLC combines all the control features that are found throughout your automation line and places them all in one centralized location; no more having to run to that red pushbutton that will stop your line. With remote access you don't even have to be anywhere near your automation line to start/stop or monitor production. With remote access you can have all the same features you have on your centralized unit in a smaller compact form. Along with ease of access from wherever you may be, simplicity is also a big factor in the usability of an Integrated HMI/PLC. With simplistic screens and functions you can train almost anyone to supervise your automation line.

A Human Machine Interface (Integrated HMI/PLC)is exactly what the name implies, it is simply a graphical interface that lets humans and machines interact. The date of birth for this interface is not known due to the huge graphical interface boom we have had, and are still experiencing. Human machine interfaces vary widely, from control panels for nuclear power plants to the screen on that new iphone, but more often than not when referring to an HMI/PLC, he/she is referring to a control panel for a manufacturing-type process. An Integrated HMI/PLC is the centralized control unit for manufacturing lines, equipped with Data Recipes, event logging, video feed, and event triggering so that you may access your system at any moment for any purpose. For a manufacturing line to be integrated with an Integrated HMI/PLC, it must first be working with a Programmable Logic Controller (PLC) because the PLC is what takes all the information from the sensors and transforms it to Boolean algebra so the Integrated HMI/PLC can decipher and make decisions.

Let us begin with other components that are necessary to making a manufacturing control system operate. First we have the production line that consists of all the machinery that do all the work in the production of the product. Next we have all the various input/output sensors that monitor temperature, speed, pressure weight and feed rate. Third we have the programmable logic controller (PLC) that will receive all the data from the input/output sensors and convert the data into logical combinations.

Though you may not know everything you may need to know at the beginning of the design process you should know that an Integrated HMI/PLC generally falls into three categories: the pushbutton replacer, the data handler and the overseer. Before the Integrated HMI/PLC came about controlling automation lines was no easy task due to the use of up to thousands of pushbuttons and LEDs all performing different tasks. The integration of PLCs and HMIs has virtually eliminated the use of pushbuttons and LEDs because any function that a pushbutton or a LED could perform can easily be done with an HMI/PLC; plus it is all in one centralized location. Oftentimes you may need constant feedback from your system, or printouts of the production reports, here is where the data handler is a perfect fit. You have to make sure that you have a big enough Integrated HMI/PLC for things like graphs, visual representations and production summaries. This type of Integrated HMI/PLC will include functions such as recipes, data trending, data logging and alarm handling/logging. Performing these tasks can be very memory intensive, so for the Integrated HMI/PLC to work as a Data handler you have to greatly consider memory. When your application involves SCADA or MES, the appropriate Integrated HMI/PLC could be extremely beneficial. With these types of applications you will need an Integrated HMI/PLC that will run windows and has several Ethernet ports also known as the overseer.

The great thing about an Integrated HMI/PLC is that you can personalize your interface however you would like. If you want to develop a complex system with multiple screens and several routines always running, an Integrated HMI/PLC fully supports that. If you are looking to program an Integrated HMI/PLC with something more simplistic you could have instructions for the controller directly written onto the HMI/PLC. Every Integrated HMI/PLC comes with different features some may play sound, play video or even may have remote access control. The design of your actual interface should be optimized for your specific application, taking into account environmental aspects and operators such as; noise, lighting, dust, vision and technological curves.

The actual physical properties of an Integrated HMI/PLC vary from model to model so it is important that you select to right one. An Integrated HMI/PLC that is located in a water plant might have various water seals around it's perimeter as opposed to an Integrated HMI/PLC that is located in a pharmaceutical warehouse. The actual size of an Integrated HMI/PLC is also a key physical property that varies, because not all applications need a large, high resolution monitor, some applications may only need a small, black and white touch screen monitor. When it comes to selecting an integrated HMI/PLC, the physical properties are extremely important because you have to take into consideration the operating environment and what safety measure the Integrated HMI/PLC has to protect itself. Also, a specific size may be needed due to space limitations. Lastly, physical properties include the processor and memory of the integrated HMI/PLC. It is important to make sure that these two are sufficient enough to control your system.

How do you control a PLC without ladder logic? How does an Integrated HMI/PLC replace the PLC software that most PLCs comes standard with? Ladder logic is simply conditional programming. For example, if input 1 is energized then coil 1 will be powered. A statement has to be true for the output to be executed. With C programming you can do the same, but in order to program an Integrated HMI/PLC to operate a PLC properly you must first know all the registers of the PLC. A good way to learn how to program a PLC via an Integrated HMI/PLC is to first start working with the PLC and the software it came with. This way you get a firm grasp on how to operate the PLC without the HMI/PLC. That knowledge will transfer over when you are ready to connect the two units together.

When considering which programming software to use there are three main categories to choose from: proprietary, hardware independent and open software. Proprietary software is the software that the manufacturer provides which is normally fairly easy to use and allows for quicker development. The drawback is that your proprietary software will only run on that specific hardware platform. Hardware independent software is third party software developed to run on several different Integrated HMI/PLC hardware. This type of software gives the developer much more freedom for the Integrated HMI/PLC selection. The downside to hardware independent software is that it is not as user-friendly as the proprietary. Open Software is the last type, and this is for the advanced programmer. This allows the developer to have complete openness in the design process.

Wiring an Integrated HMI/PLC into your system is quite easy because most likely you are already using some type of PLC. The connection between an Integrated HMI/PLC and PLC is easy as connecting a USB, RS-232, RS-485 or maybe no wires are required at all if both come equipped with wireless features. Although the wiring between the PLC and Integrated HMI/PLC may be an easy task, the wiring between the PLC and the actual automation line will be chaotic. Depending on the size and complexity of your production, you might need profibus extensions for your PLC. A profibus extension is almost like a power strip that extends one input/output to multiple input/outputs by just connecting to the expansion port of the PLC. A wiring schematic from your production line to your PLC is high recommended that way programming your Integrated HMI/PLC is sped up drastically.