Automated HMI Generation via Component-Based Virtual Engineering

Abdul Basit; Izhar Ul Haq; Muhammad Usman Qadir

Authors

Abdul Basit Department of Mechatronics Engineering (University of Engineering & Technology, Peshawar)
Izhar Ul Haq Department of Mechatronics Engineering (University of Engineering & Technology, Peshawar)
Muhammad Usman Qadir Department of Mechatronics Engineering (University of Engineering & Technology, Peshawar)

Keywords:

Human Machine Interface, Virtual commissioning, Component based automation, Programmable logic controller, Agile Manufacturing

Abstract

As system complexity rises and the demand for shorter time-to-market grows, there is a need to change our traditional methods of building automation systems. Developing code for Programmable Logic Controllers (PLCs) and HMIs is often a challenging and time-consuming part of designing automation systems. Typically, PLC and HMI codes are developed using vendor-specific tools and IEC-based languages. Secondly, code reuse usually involves a lot of manual copy-pasting, which is prone to errors. This method lacks proper version control and direct integration between PLC and HMI, making updates and maintenance not only challenging but also costly. This research provides a novel method to create an Auto HMI for component-based production machines by utilizing their associated virtual models. The production machine is initially modelled in Computer-Aided Design (CAD) tools and commissioned inside an emulated engineering environment to test and optimize the control behaviour. A methodology is presented to reuse the control data in the virtual models to build an Auto HMI. At last, the suggested solution is executed and verified on a conveyor-built system rig to demonstrate its feasibility.

References

M. R. Anwar, O. Anwar, S. F. Shamim, and A. A. Zahid, “Human machine interface using OPC (OLE for process control),” Student Conf. Eng. Sci. Technol. SCONEST 2004, pp. 35–40, 2004, doi: 10.1109/SCONES.2004.1564766.

S. Da’na, A. Sagahyroon, A. Elrayes, A. R. Al-Ali, and R. Al-Aydi, “Development of a monitoring and control platform for PLC-based applications,” Comput. Stand. Interfaces, vol. 30, no. 3, pp. 157–166, Mar. 2008, doi: 10.1016/J.CSI.2007.08.008.

C. Şahin and E. D. Bolat, “Development of remote control and monitoring of web-based distributed OPC system,” Comput. Stand. Interfaces, vol. 31, no. 5, pp. 984–993, Sep. 2009, doi: 10.1016/J.CSI.2008.09.027.

G. DiFrank, “Power of automation: An overview, technology, and implementation,” IEEE Ind. Appl. Mag., vol. 14, no. 2, pp. 49–57, Mar. 2008, doi: 10.1109/MIA.2007.914275.

E. H. Mikael Andersson, “Automatic generation of PLC programs using Automation Designer Based on simulation studies and function block libraries,” Prod. Eng. Chalmers Univ. Technol. Göteborg, Sweden, 2010, [Online]. Available: https://publications.lib.chalmers.se/records/fulltext/133762.pdf

Joakim Davidson and Tobias Sennö, “INTERACTIVE CONTROL OF A VIRTUAL MACHINE,” Lund Univ. Dep. Ind. Electr. Eng. Autom. Sweden, 2005, [Online]. Available: https://www2.iea.lth.se/publications/MS-Theses/Short article/5208_Smf_Interactive_Control_of_a_Virtual_Machine.pdf

B. Ahmad, X. Kong, R. Harrison, J. Watermann, and A. W. Colombo, “Automatic generation of Human Machine Interface screens from component-based reconfigurable virtual manufacturing cell,” IECON Proc. (Industrial Electron. Conf., pp. 7428–7433, 2013, doi: 10.1109/IECON.2013.6700369.

K. H. Lee, E. C. Tamayo, and B. Huang, “Industrial implementation of controller performance analysis technology,” Control Eng. Pract., vol. 18, no. 2, pp. 147–158, Feb. 2010, doi: 10.1016/J.CONENGPRAC.2009.09.011.

H. C. Lin, “A remote monitoring and control-based precise multilocation riveting system,” Comput. Appl. Eng. Educ., vol. 13, no. 4, pp. 316–323, Jan. 2005, doi: 10.1002/CAE.20057.

M.-J. Y. Vu Van Tan, Dae-Seung Yoo, “A Novel Framework for Building Distributed Data Acquisition and Monitoring Systems,” J. Softw., vol. 2, no. 4, 2007, [Online]. Available: https://citeseerx.ist.psu.edu/document?repid=rep1&type=pdf&doi=638b831d922b25af6347a64c49f7d3153afd4b39

E. W. Mellor, A. A. West, and R. Harrison, “A Component-Based Human Machine Interface System for Automotive Manufacturing Machines,” Proc. 7th Bienn. Conf. Eng. Syst. Des. Anal. ESDA 2004, vol. 2, pp. 361–366, Nov. 2008, doi: 10.1115/ESDA2004-58368.

J. Richardsson and M. Fabian, “Automatic generation of PLC programs for control of flexible manufacturing cells,” IEEE Int. Conf. Emerg. Technol. Fact. Autom. ETFA, vol. 2, no. January, pp. 337–344, 2003, doi: 10.1109/ETFA.2003.1248719.

E. Normanyo, F. Husinu, and O. R. Agyare, “Developing a Human Machine Interface (HMI) for Industrial Automated Systems using Siemens Simatic WinCC Flexible Advanced Software,” 2014.

S. Garbrecht, “The Benefits of Component Object-Based Supervisory System Application Development versus Traditional HMI Development in Water Systems Operations Management,” Proc. Water Environ. Fed., vol. 2008, no. 8, pp. 7358–7370, Sep. 2012, doi: 10.2175/193864708788809365.

P. Vrba et al., “Rockwell automation’s holonic and multiagent control systems compendium,” IEEE Trans. Syst. Man Cybern. Part C Appl. Rev., vol. 41, no. 1, pp. 14–30, 2011, doi: 10.1109/TSMCC.2010.2055852.

Process-Industry-News, “Rockwell Automation launches signal conditioners as first process component offering,” Assem. Autom., vol. 30, no. 3, pp. 59–63, Aug. 2010, doi: 10.1108/AA.2010.03330CAD.002/FULL/XML.

M. Bergert, C. Diedrich, J. Kiefer, and T. Bär, “Automated PLC software generation based on standardized digital process information,” IEEE Int. Conf. Emerg. Technol. Fact. Autom. ETFA, pp. 352–359, 2007, doi: 10.1109/EFTA.2007.4416789.

Volvo Car Corporation, “Programming Instructions for PLC Systems,” Simatic, 2008.

K. Güttel, P. Weber, and A. Fay, “Automatic generation of PLC code beyond the nominal sequence,” IEEE Int. Conf. Emerg. Technol. Fact. Autom. ETFA, pp. 1277–1284, 2008, doi: 10.1109/ETFA.2008.4638565.