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  PC Based Operator Interface (HMI)

 

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 THE PROBLEM: BRS’s electro-mechanical system incorporated a control panel with various push buttons, indicator lights, and gauges. The system was semi-automated but required significant operator intervention in order to function properly. Inexperienced operators made mistakes that severely damaged equipment or caused system failures. BRS wanted to re-evaluate the way the equipment is operated and develop a better approach to minimize the potential for operator error. They wanted to: 
  • Reduce the amount of required operator intervention, 
  • Limit the operator’s ability to make adjustments, and 
  • Make the entire system easy to use.

THE SOLUTION: REAL Controls evaluated several options including: 

  • Redesign of the existing control panel, 

  • Integration of an operator console with Programmable Logic Controls, and 

  • Development of a customized personal computer (PC) operator interface. 

The PC option offered the most flexible approach for future enhancements and the best option for creating the graphic interface that BRS desired. REAL Controls worked with BRS’s engineers and technicians and developed computer screen graphics and customized software. Several of the screens are shown at the top of this page. Operators are provided with computer screens that resemble the actual ice making machinery. The operator can monitor the current conditions within the refrigeration system. Any abnormal conditions set off alarms. Operators simply click a button or enter temperatures on a virtual keypad to make adjustments to the ice-rink temperature. The interface program monitors the operator’s actions and will automatically stop adjustments that might result in equipment damage or personal injury. Maintenance technicians can fine-tune and effectively troubleshoot the refrigeration system. By entering an appropriate maintenance level password, several maintenance graphic screens can be accessed. From these screens, equipment settings, such as time delays or alarm set points, can be adjusted. Additional maintenance screens enable the technician to manually start and stop equipment.

THE RESULTS: The graphic operator interface successfully meets each of BRS’s requirements. All of the information needed, by either equipment operators or maintenance technicians, is provided through the operator interface. The interface provides graphic displays that are easy to use. Information can be viewed in a variety of formats including trend charts, historical graphs, and real time lapse displays.

 

 
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