“We connect people to the future.”

Have you come into contact with an HMI today? Most likely! That’s because HMI stands for human machine interface. Quite simply, the link between people and machines. And the best example in our daily lives? The smartphone. We swipe across the touchscreen and use different apps such as email, online news, or social media channels. From controlling handy electronic devices to operating huge industrial plants, HMIs play a key role in automating and improving processes.

When it comes to operating complex machines, the HMI works via various linked screen masks that enable communication between computer programs and plant control systems, for example. In other words, the screen is used to connect to a system.

These days, the majority of the software used by the Brückner Group’s business units no longer only involves HMIs, but includes many services relating to the operation of machines and systems. This starts with process and production monitoring and also covers condition analyses, maintenance monitoring, quality analyses, and much more besides.

Modern machines and systems are becoming ever more complex. Yet it should still be possible to operate them easily and efficiently. To this end, the Brückner Group has developed innovative, user-friendly technologies.

“The task of intelligently networking our systems with our customers’ production systems is the key to greater productivity and the highest quality,” says Werner Binsmaier, Head of Engineering Electrics and Software at Brückner Maschinenbau. “That is how we are connecting our customers to the future."

Werner Binsmaier explains: “We put a high value on building not only modern systems, but above all easy-to-use systems. This means we no longer want any overloaded screen masks. Our latest HMI screens are consistently streamlined and only display the information that is needed to perform the current operating step.”

To what extent do HMI systems help to improve the service quality? Binsmaier puts it like this: “Brückner Servtec has developed a portal via which every customer can quickly contact Brückner with a single login. Whether they have questions relating to operation or wish to find out about spare parts catalogs or system documentation, they can use this special channel to request support from Brückner. Remote access to the system in question is also possible. This gives us access to every operating screen that the employees can see on-site. Such a remote session makes it possible to operate all system components in real time – just as if we were sitting right by the system, enabling us to provide instant expert support to solve our customers’ problems.”

Dr. Bernd Stein is Head of Engineering at Kiefel, another Brückner Group company: “Against the backdrop of an increasing shortage of skilled workers, there is a need to pursue new avenues,” says Dr. Stein “Then there is the huge cost pressure due to rising raw material prices and wages. The result is a desire among our customers for maximum production efficiency, while also easing people’s workload to a greater extent in individual phases of manufacturing processes.”

Dr. Bernd Stein explains: “Our research in the field of HMI improves communication between people and machines. With conventional processes, there are still too many operating steps that require extensive specialist knowledge. Intelligent logic in the machines significantly simplifies operation and, in the best-case scenario, even makes it possible for unskilled workers to use them. In addition, easier setup and startup processes can maximize production times – thereby increasing overall production performance.”

Dr. Stein explains: “Examples of our smart systems include the ability to detect the film material and thickness at the point where it is fed into the machine. Then a check is performed to determine whether the correct tool and the corresponding recipe have been loaded. Or there is the simple sensor that registers temperature changes in the production hall and regulates the heating in the machine accordingly.”

If an error occurs or the system comes to a standstill due to a malfunction, the main priority is to quickly and effectively resolve the issue and restart the machine. Dr. Stein expands on this: “We now have solutions to guide machine operators to the exact source of the problem and provide step-by-step instructions to rectify the fault.”

The major advantage of the new systems: They learn independently by rectifying errors and exceptional circumstances on the machines, thereby continuously expanding their application area.

Emanuel Heusser is Group Leader of Automation Engineering at PackSys Global, another Brückner Group company. For him, the challenge of HMI technologies lies in designing the systems in a way that allows junior employees and sometimes even unskilled workers to operate them. At the same time, the applications should be elaborate and innovative enough to meet the needs of experts with years of experience. So, how can this be done? “With elements such as the so-called tool tip feature,” explains Heusser.

“If required, it can provide a detailed description of each setting and each function. This saves the operators from having to read an instruction manual and offers them the right help for the individual applications. Beginners can use this feature to help them understand the various connections that exist within the machine. These optional aids are no obstacle to efficient operation of the systems by experts, however, because they do not take up any space on the screen unless they are intentionally selected.”

All operating elements are translated into the languages needed by customers. Yet operators from other language regions frequently also work on the machines. That being the case, the application can also be displayed simultaneously in different languages. Heusser explains: “Customer teams can operate the machine in Japanese, for example, while our service department has the system on hand in Japanese and English at the same time. It’s really straightforward.”

“With the new PackSys Global HMI system, we are taking a major technological step into the next generation of user experience,” says Heusser. “Deeper integration of the production processes into the machine is an important goal.” In other words, the machine itself should give the operators even greater support on a day-to-day-basis. When manufacturing polymer tubes, for example.

When changing tube formats in particular, many tasks have to be performed, which represent a considerable challenge for inexperienced employees. The modern system can independently tell the difference between the previous and new job and guide the operators through the necessary steps for the job change. Users can choose between concise instruction lists as a memory aid and detailed instructions for each step.

With an innovative HMI and machine software, the Brückner Group will create ever closer links between technology and people. The key is to ensure that the new systems are used to make people’s lives easier, bringing new freedom to companies – for better quality of work, for greater creativity, and for improved sustainability.