MANUFACTURING & PROCESSING FACILITIES

Process automation equipment offers significant technological advances to maximize performance on the factory floor.

To control complex processes completed by machine and automation equipment, production supervisors rely on industrial machine-to-machine human machine interface systems (M2M HMIs). They can be placed on the factory floor close to the processing lines to monitor, trouble shoot and optimize line performance. Industrial HMIs offer improved hardware, software flexibility and comprehensive device management on the factory floor.

In production facilities, industrial HMIs run the latest manufacturing software to monitor every stage of the manufacturing and processing process. They transmit data from the factory floor to the production manager and control center in real time through both wireless or wired networks (see: KVM extenders). With proper monitoring of real-time data and machine performance, industrial HMIs give operators ultimate control of line performance and the durability to withstand rigors of the factory floor. They offer more intelligent functionality in controlling the processing equipment. Industrial HMIs are built with fast processors that help ensure the accuracy in regards to batch control automation and asset management systems. They allow the operator to quickly access details of the batch in production, including time, formulation, condition and raw materials, as well as properly manage inventory, and tank allocation data. HMIs also alert production managers to line issues resulting in slowdown and enabling them to remedy issues quickly to minimize downtown.

Typical processes that industrial M2M HMIs help streamline and monitor for the food, pharmaceutical, beverage and chemical industries are including, but not limited to batch reactors, centrifuges, mixing tanks, weighing and formula analyzers.

M2M HMIs are also technological components that play a critical role in environmental and FDA regulations and compliance. To meet safety regulations, HMIs are manufactured from durable stainless steel that is both dust-tight and water resistant per IP64 or IP66 ratings. The aseptic design of the enclosure protects internal components from ingress and the beveled edges ensures that liquids or microorganisms do not accumulate in any areas.

Industrial HMI’s aseptic design is necessary to allow them to be placed on the factory floor, close to machinery, allowing for easy control and troubleshooting. As such, their industrial automation design not only allows for regular disinfecting, but also ensures that they remain operational in high electromagnetic environments and when significant motion, shocks and vibration occur on the factory floor –typical for part and component manufacturers. A shatterproof LCD display enclosed in a stainless-steel frame protects both the screen and internal components when dropped, jolted or washed down with harsh cleaning agents.

For ease of use and maintenance, industrial HMIs shatterproof LCD touch screens allow for ultimate machine control using a multi-touch projected capacitive touchscreen or an intrinsically safe keyboard and pointing device. Processing and manufacturing facilities also rely on keyboard-video-monitor (KVM) extenders

Machine Tooling
Machine tool shops require a higher level of durability from their rugged computers and displays, as compared to the technology needs of production and manufacturing facilities. They are using machine tools to cut, bore, grind, shear or alter the shape of rigid materials, typically metals.

The rugged HMIs are placed close to the machine tools to allow for operator control and precision. By placing them so close, they not only are impacted by the gyrations of the machine tools, but are also usually splashed on by the liquid (i.e. oil) used to lubricate the metal and allow the machine tool to manipulate the material more effectively.

Machine tooling facilities typically look for NEMA4X, IP65 or IP66 rated rugged displays and computers that ensures the industrial technology has been thoroughly tested and approved that it will perform well in these given environments with liquid splashing and vibrations, jolts.

Chemical, Plastics, Pharmaceutical, Food & Beverage
Pharmaceutical & food processing facilities must meet stringent regulations in terms of production, safety and cleanliness. The plant floor, including processing machinery and M2M HMIs must have a fully sealed, IP rated design. This allows it be cleaned without hazard to the technology; a daily wash down process necessary to meet the highest sanitary, hygienic standards in place to protect consumers from bacteria and food contamination.

To ensure they comply with federal regulations, all industrial equipment must be cleaned and sanitized every day, typically washed down with harsh chemical-based cleaning agents, high pressure hose directed cleaners at high temperatures. This properly disinfects the equipment. As such, industrial HMIs feature an aseptic, washdown design in a fully sealed, stainless steel enclosure that has a corrosion and chemical resistant surface with beveled edges. They are designed and tested to meet either IP64 or IP66 rating certifying that the units are dust proof and water tight.

In fact, numerous processing industries use a clean-in-place (CIP) method to ensure their equipment is properly sanitized without dissembling the units. Industrial HMIs must remain operable, without significant damage or corrosion during this very hygienic form of cleaning and are commonly used by the following industries: dairy, beverage, brewing, corn wet milling, processed foods, pharmaceutical and cosmetics.

Chemical processing facilities, including paint manufacturers, also rely on industrial and hazardous computing technology that would contain any sparks from flammable vapors. Purge control units, either built into the HMI or placed on top of the unit, do just that. The purge control will purge the unit of any flammable gasses, ensuring that the equipment inside the unit is not exposed to the surrounding flammable gas while operating. The purge control will alert the operator if a loss of positive pressure occurs or automatically cut power to internal equipment.