Automated HMI Generation via Component-Based Virtual Engineering

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.