Demand for advanced display features, communication options soars as older OIT-related technologies stumble.
If “eyes are windows to the soul,” as the French poet, Guillaume de Salluste Du Bartas rhapsodized back in 1578, then operator interface terminals (OITs) are surely windows to the process—continuous, batch, or discrete. And although it may seem a stretch to equate the soul with a manufacturing process, the fact that manufacturing is still the heart of the world economy it might as well include the soul.Keeping the operator’s (as well as the process control computer’s) eye on things is universally necessary if shifting production schedules, cost control, and product quality are to be maintained. Small wonder, OITs are have found their way into a wide variety of industries in roles varying all out large flat-panel-based color schematics/control system interface terminal to simple, monochromatic alphanumeric CRTs that have been designed to replace or augment simple pushbutton/warning light-based operator interface panels.In the recent online survey of Control Engineering readers by Reed Corporate Research, more than 180 respondents attested to the universal use of the OIT. According to those involved in specifying, recommending, and/or buying OITs, 61% purchased them for in-plant requirements and 20% used them for OEM (resale) application. The remainder (19%) was specified by systems integrators. Primary applications included 50% for both batch and continuous manufacturing, 14% for continuous processing only, 14% for discrete manufacturing, and 9% for batch manufacturing only. As in the previous survey, a surprising number (14%) indicated that their OITs were used in the other category, which includes testing and other non-manufacturing processes.According to Bill Southard, P.E., president of DST Controls, a San Francisco Bay-area system integrator, OIT use has become much more widespread in areas not normally thought of as product related. “For instance, they are showing up in a variety of applications, including temperature, time, and pressure displays on ovens, autoclaves, and cleanin-place systems. Also, while robotics are used in discrete manufacturing, their OIT’s are more involved with operation of the robot itself rather than being directly associated with the manufacture of a product. I’ve also seen OITs on forklifts in automated warehouses,”Southard adds.Assault on serial networks There were changes in preferred OIT network usage from 2003 to 2006. Ethernet TCP/IP moved from second to the top spot, overtaking RS-232. Movement among the rest of the “usual suspects”—Modbus, Modbus TCP/IP, Profibus, 4-20 mA, and such was simple place swapping or none at all. The biggest jump over the three year span between surveys was that of the proprietary network, which rose three places to the number six spot for 2006. DeviceNet declined the most, falling from fifth to take the ninth spot vacated by proprietary networks.Changes in desired communication options also mirrored the trend away from the use of serial communications. See the “communication options” section in the accompanying diagram. The survey showed significant gains in the use of OPC (from26% in 2003 to 40% in 2006), wireless (10% to 19%), and proprietary networks (48% to 53%) as communication features used for OITs. Serial communications, 72% in 2003, fell to 64% in 2006.When queried, Per Lundmark, product manager for the System 800xA Extended Operator Workplace, ABB Automation Technologies AB felt these results should be expected. “OPC is a standard for communication...it can be used with or without wireless, depending on the application and customer preference. We are using OPC 100% for connectivity in System 800xA. OPC communication to our OITs is done over Ethernet but it can be wireless if the customer wants it.”As in almost all other areas of control technology, ability to handle more data faster is driving the market. Add to this the ability to adapt wireless technology and older standards—though familiar—begin to be abandoned.Upping the feature anteSurvey respondents left no doubt what OIT features were desirable. Comparison of features that users saw as most important (and actually purchased as part of their OIT packages) is also illustrated in the accompanying diagram. Percentage pointincreases (or decreases) give a clear indication of what’s hot and what’s not.With display features the big winner was the flat-panel display, which went from 67% in 2003, to 79% in 2006. The biggest loser was the CRT—from 51% in 2003 to 42% in 2006. The evolution of flat-panel technology has had a terrific impact on its desirability. Its progress in the industrial marketplace has mirrored its acceptance in consumer electronics. OIT manufacturers have seen this coming for some time now. Kerry Sparks, product manager for Eaton Corp.’s operator interface bsiness heartily concurs. According to Sparks, there are lots of reasons for this trend.“Costs are down due to increasing volumes. Panel depth and weight are much less than CRT-based devices, allowing use of smaller enclosures or pendant-mounted enclosures where CRTs would be impractical. Pendant mounting allows the OIT to be used at varying heights, allowing operators of any stature use the screens effectively. Flat panels do not suffer from image burn-in like CRTs and are immune to color distortion in high magnetic fields in applications near robot welder, arc furnaces and smelters,” Sparks says.The biggest downside to flat-panel OIT use has been the limited life of fluorescent backlights, which required frequent maintenance due to their under 10,000-hr of use rating—a figure based on the number of hours before the backlight is at 50% of initial brightness. “Today’s backlights have a nominal 50,000-hr rating, and many flatpanel OITs now have backlight/inverter dimming circuits that are triggered by the screen-saver program assuring newer back lights may never need to be replaced,” Sparks adds. Other big winners in this category included readability at a glance (24% in 2003 to 36% in 2006), gloved-hand operation (15% to 24%), and personal computer (51% to 60%). Keypad operation dropped from 67% to 61%, and text-only capability fell from 54% to 49%.Software strategiesFor OIT-enabling software, there were dramatic changes in what users wanted with their hardware. Since the 2003 survey, Web browsers jumped from 18% to 24% in 2006. Java-enabled software and Microsoft Windows CE software also gained favoramong users. As plant-floor updates continue, Microsoft Windows NT use went from 64% to 51%. Control systems continue to evolve and applications gain complexity, advantages that control engineers can glean in assembling components and software into usable systems is helpful.Clark Kromenaker, product manager, operator interface products for Rockwell Automation, agrees. “The common theme in your reader’s responses is ‘open’ and ‘portable.’ Users want to use tools that are seen as portable, easy to use, and open. Rapidgrowth of Web services for networks, such as EtherNet/IP reinforces the growing trend of applying the best of the open computing world to a secure and safe controls environment. And let’s not forget familiarity in the world of computing—Web clients are probably one of the most used and best understood applications running on a PC. If you have a chance to work with something you are familiar with versus another method, I think you would opt for the familiar. Rockwell Automation has seen a trend toward increased interest in Web services, which has led us to add Web servers to a number of our products,” Kromenaker adds.Dropping popularity of Microsoft Windows NT is due largely to availability of other operating systems (OS). Over the past several years that Windows CE has been available for OIT applications, it has had the opportunity to prove itself as a successful and robust OS. According to Rockwell Automation’s Kromenaker, there is a good reason for this. “Most dedicated CEbased OIT operating systems are hardware constrained, which increases reliability and reduces vulnerability to malicious software. Control system designers are beginning to see advantages here beyond control-level features and benefits.”Enclosures for OITs also are an option to bring an unrated electronics up to environmental requirements. Just like the eyes, “the windows to the soul,” may need protection so does the OIT, the window to the process.
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Keeping the operator’s (as well as the process control computer’s) eye on things is universally necessary if shifting production schedules, cost control, and product quality are to be maintained. Small wonder, OITs are have found their way into a wide variety of industries in roles varying all out large flat-panel-based color schematics/control system interface terminal to simple, monochromatic alphanumeric CRTs that have been designed to replace or augment simple pushbutton/warning light-based operator interface panels.In the recent online survey of Control Engineering readers by Reed Corporate Research, more than 180 respondents attested to the universal use of the OIT. According to those involved in specifying, recommending, and/or buying OITs, 61% purchased them for in-plant requirements and 20% used them for OEM (resale) application. The remainder (19%) was specified by systems integrators. Primary applications included 50% for both batch and continuous manufacturing, 14% for continuous processing only, 14% for discrete manufacturing, and 9% for batch manufacturing only. As in the previous survey, a surprising number (14%) indicated that their OITs were used in the other category, which includes testing and other non-manufacturing processes.According to Bill Southard, P.E., president of DST Controls, a San Francisco Bay-area system integrator, OIT use has become much more widespread in areas not normally thought of as product related. “For instance, they are showing up in a variety of applications, including temperature, time, and pressure displays on ovens, autoclaves, and cleanin-place systems. Also, while robotics are used in discrete manufacturing, their OIT’s are more involved with operation of the robot itself rather than being directly associated with the manufacture of a product. I’ve also seen OITs on forklifts in automated warehouses,”Southard adds.Assault on serial networks There were changes in preferred OIT network usage from 2003 to 2006. Ethernet TCP/IP moved from second to the top spot, overtaking RS-232. Movement among the rest of the “usual suspects”—Modbus, Modbus TCP/IP, Profibus, 4-20 mA, and such was simple place swapping or none at all. The biggest jump over the three year span between surveys was that of the proprietary network, which rose three places to the number six spot for 2006. DeviceNet declined the most, falling from fifth to take the ninth spot vacated by proprietary networks.Changes in desired communication options also mirrored the trend away from the use of serial communications. See the “communication options” section in the accompanying diagram. The survey showed significant gains in the use of OPC (from26% in 2003 to 40% in 2006), wireless (10% to 19%), and proprietary networks (48% to 53%) as communication features used for OITs. Serial communications, 72% in 2003, fell to 64% in 2006.When queried, Per Lundmark, product manager for the System 800xA Extended Operator Workplace, ABB Automation Technologies AB felt these results should be expected. “OPC is a standard for communication...it can be used with or without wireless, depending on the application and customer preference. We are using OPC 100% for connectivity in System 800xA. OPC communication to our OITs is done over Ethernet but it can be wireless if the customer wants it.”As in almost all other areas of control technology, ability to handle more data faster is driving the market. Add to this the ability to adapt wireless technology and older standards—though familiar—begin to be abandoned.Upping the feature anteSurvey respondents left no doubt what OIT features were desirable. Comparison of features that users saw as most important (and actually purchased as part of their OIT packages) is also illustrated in the accompanying diagram. Percentage pointincreases (or decreases) give a clear indication of what’s hot and what’s not.With display features the big winner was the flat-panel display, which went from 67% in 2003, to 79% in 2006. The biggest loser was the CRT—from 51% in 2003 to 42% in 2006. The evolution of flat-panel technology has had a terrific impact on its desirability. Its progress in the industrial marketplace has mirrored its acceptance in consumer electronics. OIT manufacturers have seen this coming for some time now. Kerry Sparks, product manager for Eaton Corp.’s operator interface bsiness heartily concurs. According to Sparks, there are lots of reasons for this trend.“Costs are down due to increasing volumes. Panel depth and weight are much less than CRT-based devices, allowing use of smaller enclosures or pendant-mounted enclosures where CRTs would be impractical. Pendant mounting allows the OIT to be used at varying heights, allowing operators of any stature use the screens effectively. Flat panels do not suffer from image burn-in like CRTs and are immune to color distortion in high magnetic fields in applications near robot welder, arc furnaces and smelters,” Sparks says.The biggest downside to flat-panel OIT use has been the limited life of fluorescent backlights, which required frequent maintenance due to their under 10,000-hr of use rating—a figure based on the number of hours before the backlight is at 50% of initial brightness. “Today’s backlights have a nominal 50,000-hr rating, and many flatpanel OITs now have backlight/inverter dimming circuits that are triggered by the screen-saver program assuring newer back lights may never need to be replaced,” Sparks adds. Other big winners in this category included readability at a glance (24% in 2003 to 36% in 2006), gloved-hand operation (15% to 24%), and personal computer (51% to 60%). Keypad operation dropped from 67% to 61%, and text-only capability fell from 54% to 49%.Software strategiesFor OIT-enabling software, there were dramatic changes in what users wanted with their hardware. Since the 2003 survey, Web browsers jumped from 18% to 24% in 2006. Java-enabled software and Microsoft Windows CE software also gained favoramong users. As plant-floor updates continue, Microsoft Windows NT use went from 64% to 51%. Control systems continue to evolve and applications gain complexity, advantages that control engineers can glean in assembling components and software into usable systems is helpful.Clark Kromenaker, product manager, operator interface products for Rockwell Automation, agrees. “The common theme in your reader’s responses is ‘open’ and ‘portable.’ Users want to use tools that are seen as portable, easy to use, and open. Rapidgrowth of Web services for networks, such as EtherNet/IP reinforces the growing trend of applying the best of the open computing world to a secure and safe controls environment. And let’s not forget familiarity in the world of computing—Web clients are probably one of the most used and best understood applications running on a PC. If you have a chance to work with something you are familiar with versus another method, I think you would opt for the familiar. Rockwell Automation has seen a trend toward increased interest in Web services, which has led us to add Web servers to a number of our products,” Kromenaker adds.Dropping popularity of Microsoft Windows NT is due largely to availability of other operating systems (OS). Over the past several years that Windows CE has been available for OIT applications, it has had the opportunity to prove itself as a successful and robust OS. According to Rockwell Automation’s Kromenaker, there is a good reason for this. “Most dedicated CEbased OIT operating systems are hardware constrained, which increases reliability and reduces vulnerability to malicious software. Control system designers are beginning to see advantages here beyond control-level features and benefits.”Enclosures for OITs also are an option to bring an unrated electronics up to environmental requirements. Just like the eyes, “the windows to the soul,” may need protection so does the OIT, the window to the process.
