Author name: Christopher

Like any other machine, an HMI can break, and before you can fix it, you need to find out what the problem is. T2Industrial has a team of industrial control experts and with their help, we have identified 5 common HMI failures that users encounter. What Is An HMI? The complex set of machines that make up an automated system requires accessible connections between the machine and the person operating it. HMI stands for human-machine interface. This interface is usually a screen or panel through which a person can connect to any device, machine, or system. A human-machine interface (HMI) can be anything that lets you interact with electronics, including your smartphone. Today’s automated facilities increasingly use HMIs in addition to various visual control panels. Although other terms may be used to refer to this technology, such as operator interface terminal (OIT), local operator interface (LOI), and man-machine interface (MMI), HMI is the most common. It is sometimes used to refer to a graphical user interface (GUI), but these are not the same thing. A graphical user interface allows the user to navigate the screen using images or icons rather than text or commands. It has similar capabilities to an HMI but is generally used to enable visualization within the HMI. An HMI can take the form of a tablet, computer monitor, or screen built into the machine, but all of these give operators insight into machine performance and progress. Industrial HMIs are typically used for auditing purposes, including monitoring inputs and outputs, tracking key performance indicators, tracking production statistics, and providing visual representations of key data. In factories, HMI can be used to monitor pump functions, control safety systems, manage production lines or maintain optimal working conditions for personnel. Most home HMI functions are basic versions, such as controlling your washing machine or air conditioner, and your smart home can be completely controlled with a single tablet. HMI Health The HMI constantly gives feedback on its status and provides a lot of information about possible errors in the future. This is important because if an error occurs while the HMI is operating, the equipment also shuts down, resulting in costly downtime and lost productivity. How can we interpret this information to prevent this from happening? From our HMI experience at T2 Industrial, these are the 5 most common HMI faults to watch out for. 1. DIFFICULTY POWERING-UP If your HMI tries to turn on repeatedly or requires frequent power cycling (resets), this is a typical sign of premature failure. An HMI initialization problem indicates an imminent failure of the internal power supply. 2. UNRESPONSIVE KEYPAD Keys that are commonly used in HMIs are prone to failure at first. Keys such as the Start, Enter, or password keys may be used frequently and identification symbols may be worn out. Operators may find that they press a key a little harder each time, and eventually, these keys fail. This indicates a faulty switch and you will need a new switch or even a whole new membrane. 3. LESS RESPONSIVE TOUCHSCREEN Some common parts of the touch screen may fail or force the operator to press a soft button repeatedly to get a response. This is a sure sign of a malfunction of the touchscreen element. Touch screens are very sensitive and wear out like any other part. You must use nothing but your fingers to work with them, otherwise, they may itch and break. Breaking the LCD glass can cause the HMI to fail immediately, and moving the screen with a pen or other tool increases this risk. 4. DULL OR FLICKERING SCREEN This can be annoying for the operator, but it is more important because it indicates an immediate HMI backlight failure. The backlight can take several months to completely fail, so you have plenty of time to install a replacement unit or upgrade the HMI. 5. LINES ON THE SCREEN Vertical or horizontal lines on the screen are equally annoying, but they indicate an early malfunction of the LCD screen. Like the flickering, it starts appearing on a few lines and takes some time to stop completely, but that is a sure sign of failure. Preventative Maintenance Many of these symptoms appear months before a complete failure occurs, so an ongoing conversation with system operators must be initiated to prevent this from happening. They are the ones who interact with the HMI every day and tolerate small problems instead of fixing them. If operators learn to recognize these 5 early indicators of common HMI failures, they can more easily manage their system without sudden and unexpected failures. Here’s some predictive maintenance that takes the form of simple questions. Does the HMI start immediately every time? Do your touch screens or membrane keys react less? Have you noticed that the screen flickers or looks dull? Do you see any lines on the screen? The operator’s answers to these questions should inform you about likely HMI failures and the need for refurbishment or replacement. Don’t wait for an operator to tell you after a break that some of these symptoms have been occurring for months. They don’t go away on their own and preventative maintenance helps avoid downtime and loss of production. By following these simple predictive maintenance questions, you can prepare ahead of time what replacement parts to look for. If you need guidance or any help on how or what to replace your HMI, our team of experts is available just give us a call or send us an email. We have multiple replacement parts for units like Allen-Bradley, Siemens, Anilam, Dynapro, Fanuc, and a lot more. You can check our product catalog here.

Automation requires Human Machine Interfaces (HMIs) to operate and track machines. These gadgets offer a touchpad and visual interface for managing production procedures and carrying out regular duties. The Automated Teller Machine (ATM) is among the most well-known HMI devices (ATM). To easily conduct bank deposits and disburse cash withdrawals, these ATM systems include an easy user interface with a keypad and display. For our regular financial requirements, they offer dependable 24-hour access. There are a lot of different HMI devices in the industry. Several older HMI devices use the original Cathode Ray Tube (CRT) monitor technology. The owner and users of this outdated technology must deal with a number of drawbacks: A High Energy Requirement It is not thought that CRT technology is energy-efficient. The energy consumption is higher than more recent LCD technologies. A CRT screen uses three to four times the energy of an LCD screen. Costly to Maintain As the workforce migrates to the newest technology, CRT repairs become more specialized and expensive. Obsolete Components CRT technology has reached the end of its useful life. Repair-related components are getting harder to find and more costly. Avoid Purchasing Expensive New Operator Interface Packages T2 Industrial LCD technology updates keep the interface packages for your current equipment in place (frames, communication connections, power sources, etc.). T2 Industrial updated HMIs are plug-and-play. Better Reliability The life of the electrical circuit components is frequently shortened by the heat produced by CRT technology. CRT displays typically last between 18,000 and 20,000 hours. The lifespan of an LCD display is greater than 100,000 hours. Picture Clarity, Sharp Image The screen burn that is frequently associated with CRTs is no longer an issue thanks to LCDs. For the operator, the LCD visual display is significantly better and won’t fade. To replace your outdated CRT displays with LCD technology and new keypads, check our product catalog. This strategy involves minimal risks and a low-cost upgrade to better technology. For an immediate quotation on repairing, replacing, or buying replacement parts, visit our product catalog page, give us a call or send us an email. We have multiple replacement parts for units like Allen-Bradley, Siemens, Anilam, Dynapro, Fanuc, and a lot more. You can check our product catalog here.

Your Human Machine Interface (HMI) units are essential to the operation of your business. They facilitate the efficient and simple operation of your equipment and take the place of more intricate units in your production facilities that have hundreds of buttons and switches. These interfaces are prone to breakage, screen failures, and other issues because of their constant use. It’s critical to utilize your interface appropriately since, over time, the device may develop reliability issues due to heavy use. How do you determine when to change your HMI unit?   1. Insufficient Lighting on the Screen It may be necessary to replace the display if the backlights or inverter circuit stopped working, the screen is poorly lit, difficult to see, or the graphics are improperly shown. Some HMIs like Allen-Bradley PanelView 500 have screen dimming or “patchy” areas because the incandescent light bulb that illuminates the display becomes so hot that they melt the fiber optic connections. When this occurs, the screen effectively ceases to work and becomes unsafe to use since incorrect choices may be made. This might lead to equipment damage, machine malfunctions, or even the possibility of an accident involving your operator. To avoid this, we at T2 Industrial replace this with an LED that is not hot.   2. Touchscreen Is Not Responsive Anymore It’s time to replace your HMI device when you can’t make selections on your touchscreen anymore. To make a choice, you might need to push firmly or attempt numerous times. Your touchscreen is broken if this occurs, regardless of whether it was caused by heavy use, a bad connection, or a loss of calibration. The accumulation of materials such as dirt, oil, or other contaminants may have an impact on the functionality of your touchscreen. Your ability to make accurate choices might be impacted by the touchscreen’s alignment.   3. Defective Cable Connectors The communication port or cable may be troublesome if the connection between your PLC and HMI is compromised. It’s conceivable that the driver chips for your communication ports have stopped functioning if contact between the two cannot be established. A failure on your PLC and HMI might result from intermittent communication, which could lead to incomplete data transfers. When a connection cannot be made, your HMI has to be replaced or repaired.   4. Broken or damaged screen When your HMI is used incorrectly, for as by using screwdrivers or hard objects to touch the screen, rather than your fingertips, the entire device may be harmed. This includes the touchscreen, keypad membrane, screen overlay, and display. The effectiveness of the HMI unit will be adversely affected by all of these factors. A cracked or damaged screen should be replaced because it will surely affect input. You don’t need to acquire a new HMI if your current one is causing any of these issues.   In summary, if you are experiencing these with your HMI units, we suggest considering replacing your screens as it is more costly for your business to replace the whole unit. We have multiple replacement parts for units like Allen-Bradley, Siemens, Anilam, Dynapro, Fanuc, and a lot more. You can check our product catalog here.