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1、WhitepaperAdvantages of Wireless Human-Machine Interface(HMI)for Industrial AutomationHow leveraging Bluetooth in industrial devices can transform the user experience and improve product lifetime valueMikko Niemi and Parker Dorris UTILIZATION RATE90%CAPACITY|Advantages of Wireless Human-Machine Inte

2、rfaces(HMI)for Industrial Automation2While todays consumer products offer enhanced connectivity and a more immersive user experience through innovative HMI designs,industrial products continue to employ physical interfaces typically featuring HMIs that rely on small displays or simple LEDs and resor

3、t to electromechanical switches or pushbuttons as their primary means of interaction.If a device features local connectivity,it is typically implemented using cables and physical connectors.There is great potential to improve the user experience by transforming the way industrial products are interc

4、onnected,and this presents an opportunity for innovative vendors to differentiate their products in an increasingly crowded market.Industrial device HMI presents significant challenges for designers.Product design specifications may be guided by standards;devices may have limitations on their physic

5、al size,and controls may need to be fitted to larger installations.Products used in industrial settings represent critical capital investments that are expected to reliably remain in service for many years,even as their local ruggedized interfaces are subjected to diverse stress factors.Safety is al

6、so an important consideration.Products must remain safe to operate when connected to other equipment,such as computers,which typically requires the use of galvanic isolation on all external ports.Modern,standards-driven wireless technologies,such as Bluetooth,present designers with new tools that ca

7、n help them transform the user experience for industrial devices.In addition,human-machine interfaces based on Bluetooth offer cost savings compared to conventional wired connectivity solutions.Bluetooth Offers a Superior User ExperienceContents:Creating a better,more efficientuserexperience with Bl

8、uetooth Increased cost savings andfutureproofingwith wireless interfaces Embedded systems and mobile phone accessHuman-machine interfaces(HMI)are ubiquitous and have become the subject of a tremendous amount of development in recent |Advantages of Wireless Human-Machine Interfaces(HMI)for Industrial

9、 Automation3UsingBluetoothwithindustrialdeviceseliminatesthephysicaldependenceonspecificconnectortypesby enabling end-users to connect to their devices wirelessly using any Bluetooth-enabled device.Nearly all devices,including smartphones,tablets,and laptops,support Bluetooth,which clearly illustrat

10、es theplatform-independenceofthistechnology.Thiscanbeextremelybeneficialforend-customersasthey are no longer limited to using custom devices that are physically and electrically compatible.Even competing operating systems and product brands become compatible by using Bluetooth.Withtheincreasedflexib

11、ilityofBluetooth,developersarefreetocreatemoreinnovativeandintuitivegraphical user interfaces by leveraging mobile applications and are no longer restricted by device dimensions or the need to accommodate physical buttons.Easily understood user interfaces not only provideanaestheticallypleasingexper

12、iencebutcanalsoreduceuser-relatederrors.Intuitivescreenscanhelpinnavigatingfeaturesandprovideuserswithclearinstructions,asopposedtothecomplexsequences of button pushes used in conventional designs.Thus,the time required to train operators on newsystemscanbereduced,providinganadditionalbenefittoendcu

13、stomers.Whenaccesstodevicesanddataissimplified,newdata-drivenusecasesandfeaturescanbedeveloped.Theseincludereducingthetimeneededtoreconfiguredevicesettingsoraddingfeatureslike predictive maintenance by accessing and analyzing operational data.These operations can be accomplished over-the-air without

14、 impacting normal operations.And,by introducing cloud connectivity,operator errors can be addressed by distributing the new settings centrally from a hosted database instead of relying on them to be programmed locally by operators.Removing Physical Connections Can Deliver Cost Savings SYSTEM ACCESS

15、ERROR CODES|Advantages of Wireless Human-Machine Interfaces(HMI)for Industrial Automation4Bluetoothofferssignificantcostsavingscomparedtotraditionalhuman-machineinterfaces.Galvanicallyisolated serial ports are one of the most common interface technologies in the industrial device market.The bill of

16、materials cost for a system-in-a-package Bluetooth module can be up to 48%lower than that of an isolated serial port,and,if the device also has a local LCD display and electromechanical components,such as switchesandpushbuttons,thecostdifferencebecomesevengreater.Further savings can be derived from

17、reduced maintenance costs.With Bluetooth,there are no mechanical parts accessible to the user;thus,there are no failures associated with those components,resulting in fewer product returns.For end customers,a wireless interface removes the possibility of experiencingmechanicalfailurescausedbymishaps

18、likebrokenconnectors,thus avoiding costly repairs.Improving Future-Proofing and Security through Wireless InterfacesIndustrialdevicesareexpectedtohaveaworkinglifeofmanyyears,whichgreatlyexceedsthetypicallifetime of most consumer products.Over this time,new features are inevitably developed to meet e

19、volving market requirements.Adding new functionality to industrial devices can be a cumbersome process because they are often located in places with limited physical access or where access requires substantialeffortandcosts.Byusingover-the-airfirmwareupdates,wirelesstechnologyprovidesa much simpler

20、channel for upgrades.For end-customers,device upgrades provide new ways of leveraging their initial investment,and device manufacturers are empowered to implement new business modelsfocusedonsellingoptionalsoftware-enabledfeatures,whichcanextendthelifetimerevenueoftheir products.Like all software,mo

21、bile applications require maintenance,and the underlying operating systems continue to evolve.When selecting a Bluetooth vendor,a device manufacturer should pay close attention to their vendors commitment to maintaining both the Bluetooth stack as well as the mobile application libraries.A vendor th

22、at provides timely and tested updates to their libraries when new major versions of the operating systems are released is preferred.Industrial systems are increasingly becoming the targets of cyberattacks.In addition,there is a growing numberofregulationsalreadyinplaceorbeingplanned.Anexampleofonere

23、centregulationisSB327in California,which sets forth rules for internet-connected devices.While Bluetooth inherently includes security features,such as encryption,it is not enough to rely on the security provided by the standard itself.Device manufacturers should ensure that their Bluetooth vendors h

24、ave a strong security posture andthatwirelessSoCsandmodulesincludeadvancedfeatures,suchassecure boot,to prevent unsignedfirmwarefrombeingexecutedontheirdevices.Cloud connectivity is becoming mainstream in the industrial IoT.By combining Bluetooth with modern mobile operating systems,secure cloud con

25、nectivity becomes much simpler than updating legacy desktop applications.Moreover,cloud applications make software update delivery more centralized.As theIndustry4.0wavesweepsthroughdifferentmarketverticals,thedemandforcloud-basedsolutionsis predicted to continue its growth |Advantages of Wireless H

26、uman-Machine Interfaces(HMI)for Industrial Automation5Reducing the Number of Electromechanical Devices will Improve ReliabilityWhat is the mean time before failure for a push-button or display?How many mating cycles can a physical connector endure without fault?These,among many others,are questions

27、designers must consider for devices with physical user interfaces.Conversely,wireless technologies are not subject to mechanical stresses,and removing a physical interface means that there is one less variable to consider when hardening a design for industrial environments.Anything that physically c

28、onnects to a device requires an opening in the enclosure.Because industrial devices are often deployed in variable and harsh environments,such openings must be protected against dust,water splashes,and other conditions that could damage the device or its parts.With Bluetooth,device enclosures can be

29、 completely sealed.If LED indicators are used,even they can be placed inside an enclosure and observed through a translucent barrier.The reliability gains made possible through the use of Bluetooth can deliver real cost savings for device manufacturers and end customers.These include:Less time spent

30、 on designing the enclosure to withstand harsh environments,which results in faster time-to-market.Reduced number of electromechanical components,which are commonly very costly compared with semiconductor parts;so,removing these costly components from the design also improves gross margin.LowerTotal

31、CostofOwnership(TCO)forendcustomerssinceasimplifiedhuman-machineinterfaceusing Bluetooth requires less maintenance.Industrial environments in which large numbers of machines and equipment contribute to RF noise levels are known to be a challenge for radio technology.Because Bluetooth uses frequency

32、hopping,it is better equippedtowithstandRFIfromvarioussources.Thisisanimportantconsiderationsincethe2.4GHzISM band is used by many applications and technologies.An interferer blocking one or more channels will be unable to entirely disrupt communications.Therefore,Bluetooth is also suitable for indu

33、strial settings.TEMPERATURE SETTINGSBluetooth Connectivity Design ConsiderationsThere are a variety of ways to add Bluetooth connectivity to an application.In cases where a developer hasacombinationofin-houseBluetoothdesignexpertise,embeddedfirmwareandmobiledevelopmentteams,andtheresourcesnecessaryt

34、otakeadesignthroughtheRFcertificationprocess,designingaBluetooth-enabledSoCsolutionintoanapplicationcanbecost-effective.Pre-integratedandpre-certifiedwirelessmodulesareanidealsolutionforcompanieswithlimitedwirelessproductdesignexpertise.Choosinganintegratedmodulewithpre-certifiedRFandhardwareenables

35、 companies to spend less time adding wireless technology to their designs.ThebenefitsofchoosingaBluetoothmoduleinclude:Integratedantennaoptions,whichminimizestheneedforin-houseRFexpertise Pre-certification,whichavoidslengthyandcostlyRFcertificationefforts Out-of-the-boxperformancethatmeetsmostneedsP

36、reprogrammed Modules Offer BenefitsAdding Bluetooth connectivity using modules still requires a degree of familiarity with Bluetooth protocolsaswellasanunderstandingofhowtoexerciseavendorsBluetoothstackandassociatedAPIs.In many Bluetooth-enabled applications,developers must also create an embedded h

37、ost that interfaces with the Bluetooth-connected coprocessor(NCP).This host-to-NCP communication link usuallyexposeslow-levelcontroloftheNCP,andtheembeddedhostmustdevotesignificanton-chipresourcestomaintainbuffersandmonitorthestatusoftheNCPsBluetoothlink.Inordertomeettheserequirements,engineersmaybe

38、temptedtoselectanembeddedhostthatisover-specifiedandcarriesahighercostthantheapplicationactuallyrequires.Theover-specifiedMCUmayalsoconsumemorepower than is necessary.Evaluatingtherightsolutionpresentsitsownchallenges,however,asdevelopersmustexploreallpossibleuse-casesandevaluatehoweachonemayaffectf

39、unctionality.Itisalsonecessarytotestasmanyofthesescenariosaspossibletoseeiftheapplicationfunctionsasexpectedandthentroubleshootorfixbugsastheyarise.Thiscanpotentiallyinvolvecomplexdebuggingacrossboththehost and NCP development environment.Fortunately,Bluetoothdesigncanbefurthersimplifiedbyselectinga

40、precertifiedmodule,preprogrammedwithBluetoothfirmware,todeliverout-of-the-boxconnectivity.Thebenefitsofpreprogrammedmodulesinclude:Access to a Bluetooth stack and embedded applicationfirmwarethatispreprogrammed,eliminatingtheneedforfirmwaredevelopment Gainingaproduction-leveltestinginfrastructure bu

41、ild-upforstackandfirmwarehandledbythe module vendor Built-insupportforfirmwareupdatesand boot-loading,thusfuture-proofingforsecurity updates,bugfixes,|Advantages of Wireless Human-Machine Interfaces(HMI)for Industrial Automation655PRECERTIFIEDMODULES|Advantages of Wireless Human-Machine Interfaces(H

42、MI)for Industrial Automation7Expediting Connections Between Embedded Systems and Mobile PhonesAs outlined earlier,the advantages of using Bluetooth include access to a wide range of potential user interface design resources and,particularly,the convenience of using a tablet or other form of mobile d

43、evice as a controller.However,mobile app development is a specialized area,so it is often an element of product design for which manufacturers will need to engage outside development services.Developers who know how to properly write application code that can interface with low-level Bluetooth APIsi

44、nbothiOSandAndroidplatformsarerelativelyrare,andservicesofferingthisspecializedskillcanbecostly.Companiesmightalsoneedtoengageseparateexpertsforeachplatform,whichaddsup-frontcostsandintroducestime-consumingprojectsetupdifficulties.Startingmobileappdevelopmentusingawirelessinterfacelibrarythathasbeen

45、developedandprovidedbythemodulevendorcansignificantlylowerbarrierstoentryintomobileappdevelopment.Amobilelibraryspecificallydesignedtointerfacewithachosenpreprogrammedmoduleprovides:An abstracted interface to core Bluetooth APIs across multiple mobile operating systems SpecializedAPIsdesignedforopti

46、malcontroloftheinterfacingembeddedmodule Acloud-to-modulerouteforfirmwareupdatesSiliconLabsBluetoothXpress products combine these development optimizations to provide streamlined embedded-to-phone connectivity.BluetoothXpressproductscombinefirmware,hardware,andmobiledevelopmentoptimizationstodeliver

47、 Bluetooth Low Energy 5 modules that can reduce the time required to take an application from concepttoprototypetojustoneday.BluetoothXpressproductsincludetheXpressframeworkformobile application development,which greatly reduces the development time required to add Bluetooth connectivity to mobile a

48、pps.The key features of SiliconLabsBluetoothXpressmodules(BGX220P and BGX220S)are:Anout-of-the-box,preprogrammed,precertifiedBluetoothsolutionsupportingBluetooth5featuresincluding2Mandlong-rangePHY Onboardwirelessstackscontrolledthroughahigh-levelGeckoOSXpressCommandAPIforsetupand control Baudrate,f

49、lowcontrol,GPIO,andBluetoothperformanceparametersthatareallconfigurableforapplication-specificrequirements AnI2CmasterinterfaceenablesBluetoothLowEnergywireless-to-I2Ccommunication Input pin monitoring for automated digital logic transition response Requires only modest resources from a host process

50、or,enabling developers to add wireless connectivity to any MCU AvailableinbothPCBandSiPformfactors One point of contact for design support SupportforSecurityandFirmwareupdates DIAGNOSTICS DATA ANALYTICS|Advantages of Wireless Human-Machine Interfaces(HMI)for Industrial Automation8BluetoothXpressmodu

51、lesfunctioninthreeusecases:1.BGX220tosmartphoneInthisusecase,theBGXactsasaperipheral,whichisdiscoverableandconnectable by a smartphone.2.BGX220toBGX220Inthisusecase,oneBGXactsasadiscoverable,connectableperipheral,andasecondBGXactsasthecontrol,whichscansandconnects.Whenconnected,aBGX220canfunctionin

52、either a streaming mode,where data bytes are transmitted between the two points in a no-overhead datastream,orincommandmode,whereBluetoothXpresscommandscanbeexecutedremotely.3.BGXwithnoembeddedhostThisusecaseisavariationofusecases#1and#2.Inthiscase,onboardBluetoothXpressfunctionality,suchasinputpinm

53、onitoring,eventnotifications,andtheBluetooth-to-I2Cbridge,providefunctionalitythatissufficienttotakeonallresponsibilitiesoftheembedded host processor.Inthesedefinedusecases,flowcontrolsignalsfromtheBGXindicatebufferstatusandcanbeusedtoindicate whether the embedded host can transmit data.Figure A:Blu

54、etooth modules can be deployed in many ways to meet applications specific needsFigure4.2.BGXtoPhoneUseCasei2cwr f0 23 Host MCU Wireless XpressFigure4.1.BGXtoBGXUseCase Host MCU Wireless Xpress Host MCU Wireless X|Advantages of Wireless Human-Machine Interfaces(HMI)for Industrial Automation9Configura

55、tion and Communication with Bluetooth XpressAsystemcontrolsBluetoothXpressspreprogrammedfunctionalitythroughacommandinterfacethatisconfigurableatruntime,withdefaultsettingsthataresavedtonon-volatilememory.Thisinterface,whichisavailablethroughserialinterfacepinsandexecutableover-the-airthroughtheBlue

56、toothInterface,functions as a high-level network coprocessor.Inmostoperationalstates,BluetoothXpressactsasazero-overheadBluetooth-to-serialdatastream.Forexample,aBluetoothXpressmodulecansignaltoanembeddedhostthataconnectionhasbeenestablishedbychangingthestateofaportpin.Atthepointofconnection,theRXan

57、dTXpinsoftheserial interface act as a bidirectional data interface,functioning identically to a wired serial link.Data can bewrittenfromthehosttotheBluetoothXpressmodulesRXpin,andBluetoothXpressthentransmitsthat data byte-by-byte across the BLE link.On the other side of the BLE link,either a smartph

58、one receivesthedataanddeliversabuffertoamobileapporanotherBluetoothXpressmodulereceivesthedata.ThisreceivingBluetoothXpressmodulethensendsthedataoutthroughitsTXpintobereceivedby the remote embedded host.Leveraging Bluetooth for Industrial Automation HMIsManyindustrialautomationdevicesuseserialprotoc

59、olsforlocalconfigurationanddiagnosticports.Thetechnology is well-known and widely supported.While many of these physical serial ports have become ararecommodityinmodernlaptops,virtualCOM-portdriversallowUSBtobeusedinstead.Thislegacyarchitecture is now fertile ground for Bluetooth-based human machine

60、 interface alternatives.The picture shown in Figure B,(page 10)outlines a conventional industrial automation device that supportsalocalconfigurationanddiagnosticsportusingaserialinterface.Thecableinterfaceintroduces challenges that also add to product cost while decreasing convenience and negatively

61、 impactingtheoveralluserexperience.To ensure user safety,the cable interface is galvanically isolated from the rest of the industrial automationdevicescircuitry.Inaddition,thecableinterfacerequiresanICtoprovidetheRS-232driverand the actual physical serial port.These,and the required passive componen

62、ts,add to the device bill of materials and increase the PCB space required.The cable interface may also impose a physical access challenge.In cases where the device is installed in hard-to-reach locations,it may not be possible to connect the cable to the device.This means that the deviceisonlycapab

63、leofdeliveringpartofitspotentialfunctionalityandbenefits.AUTOMATE ROTATION SETTINGS|Advantages of Wireless Human-Machine Interfaces(HMI)for Industrial Automation10NowconsidertheexampleinFigureC,whichillustratesthesameindustrialdeviceenabledwithaSiliconLabs BGX220BluetoothXpressmodule,whichisdesigned

64、foreasycablereplacementscenarios.TheapplicationCPUcouldcontinueusingtheexistingUARTinterfacebecauseBluetoothXpresssupportsthe transfer of serial data over the Bluetooth link.This greatly reduces the time and risk associated with the Bluetooth integration since the designer does not need to have any

65、prior knowledge of Bluetooth.All intelligenceisbuiltintothestackandapplicationfirmwarerunningonthemodule.BluetoothXpressalsosupportsSPIinterfacing,shouldthatbemoresuitablefortheapplication.BluetoothXpressmodulescomeindifferentformfactors,withthesmallestSystem-in-Packagemodelbeingonly6x6mminsize,maki

66、ngitidealforspace-constrainedapplications.Becausethemodulealso includesanantenna,thedesignerhasmoreflexibilityintheplacementofthemoduleonthecircuitboard.An important point is that using Bluetooth for the human-machine interface does not replace or impact the useoffieldbuscommunications.Thismaintains

67、backwardscompatibilitywiththepreviousgenerationofdevices,something that is valued by many industrial automation device customers.By removing the galvanic isolation,serial interface driver,and physical connector,the bill of materials can besimplifiedandproductcostsrelatedtothecableinterfacereducedbyu

68、pto48%.Removingthephysicalconnector also eliminates the need for enclosure openings to make the connector accessible to the user.Shouldtheconnectorrequireextraprotectionagainstenvironmentalconditions,suchasdustormoisture,an even greater cost savings can be achieved,as those protectors are no longer

69、needed with the Bluetooth-based solution.Figure C:An example application using Bluetooth for cable replacementBluetooth XpressBGX220Smartphone/TabletSensorsPower SupplyApplication CPUIsolationField Bus I/OI2CSPIAnalogUARTRF-linkRS-485Industrial Field DeviceHuman-MachineInterfaceFigure B:A convention

70、al approach to product design using a serial port with galvanic isolationPower SupplyApplication CPULaptopSensorsGalvanicIsolationSerial PortDriverIsolationField Bus I/OI2CSPIAnalogUARTUARTUARTRS-485Industrial Field InterfaceHuman-MachineI|Advantages of Wireless Human-Machine Interfaces(HMI)for Indu

71、strial Automation11This architecture allows users to wirelessly connect multiple devices from a single location without requiring physical access to the devices,which can also improve functional safety.This makes it possibletomodifydeviceconfigurationsmoreflexiblyanddownloaddiagnosticdatastoredindev

72、icesfor analysis and troubleshooting.Bluetooth,by default,includes data encryption and hashing,which adds another layer of protection against cyber threats.Asoutlinedabove,themobileapplicationframeworkthatcomeswithBluetoothXpressproductssignificantlysimplifiesBluetoothintegration.Byabstractinglow-le

73、velBluetoothfunctionalitytobeaccessed via an API,device manufacturers can achieve faster time-to-market as valuable development effortsarespentonaddingfunctionalityratherthanlearningBluetoothspeculiaritiesforAndroidoriOS.And mobile applications also support cloud connection,which can be used to prov

74、ide new cloud-based productofferings.ConclusionBy its nature,Bluetooth is hardware-agnostic.A growing number of devices now support Bluetooth connectivity,whichmeansitisaneffectiveabstractionlayerbetweenlow-levelfunctionalityandhigh-levelcontrol and monitoring features.ThebenefitsofBluetoothinindust

75、rialenvironmentsarenumerous.Asacable-replacementtechnology,itis already a proven solution with applications in HMI design.Adding Bluetooth connectivity using a module likeSiliconLabsBluetoothXpresscandeliversignificantandmeasurablesavings.Costlycomponentsrequiredforphysicalcableinterfacescanbeelimin

76、atedandsignificantcostreductionsachieved.Moreuser-friendlyinterfacescanbeprovidedusingmobileapplications,andfunctionalitycanbefurtherextendedbyconnecting applications to the cloud.With readily available APIs for easy integration at the board,link,and mobile application levels,the Bluetooth Xpresspor

77、tfolioisanidealsolutionforreplacingexistingcableinterfaceswithserialcommunications.Usingpre-certifiedmodulesenablesfastertime-to-marketasdevicemanufacturersnolongerhavetoworryabouttime-consumingcertificationprocessesandcaninsteadfocusonmarketingeffortstomaketheirdevicessuccessful.Kickstart your wireless HMI project by ordering the BluetoothXpressevaluationkithere.Watch the“Transforming HMI in Industrial Devices Using Bluetooth”on-demand webinar where the authors discussed and answered questions on HMI&BGX220.DATA COLLECTION MAINTENANCEWatch Now