Consider the Machine
Collect Data from the Machine and Display it For the Operator
Think about the machine and application: what data from the machine do operators need to be aware of? Maybe it’s temperature, pressure, position, or something else entirely. Knowing what machine data the operator will need gives you a good idea of what sensors need to be included in the machine design.
Next up is how will you display this information? When designing the solution, try to envision yourself in the shoes of the operator. How would you want to see the data displayed? Do you simply want to see a temperature gauge, whose reading you have to interpret, or would you rather a custom warning come up when the temperature rises too high?
Use CANbus/CANopen to Simplify Design and Manufacturing
CANbus for mobile equipment or CANopen for industrial machines can greatly simplify manufacturing of any machine. Instead of relying on point-to-point wiring, where every control element needed to be individually wired, the CAN system allows for the controller to be plugged into a central Programmable Logic Controller (PLC). Using this method, controls can be wired in much less time, speeding up the manufacturing process.
Before and after of a system moving from traditional wiring to a CANbus system.
Centralize Control to One Single Panel
Additionally, think about how to control both the engine and the machine itself. Can these controls be integrated into a single human machine interface (HMI)? Doing so can be a significant value add to the OEM. One central controller is less expensive for the OEM to purchase and the simpler design will be easier to manufacture, saving both time and money.
Streamline Maintenance
When thinking about integrating electronics, think of the benefit you can provide. Can you create a value add by making the machine more reliable? With all the data flowing into the controller, think about what value you can add to the end user. Can you set up a predictive maintenance program where the machine can tell operators when parts are nearing failure? Can the controller help create an efficient maintenance schedule that helps minimize downtime while potentially getting the longest life possible out of each component?
Consider the User
Create a Simple User Experience
Think about the user when designing your machine. Does your design make it easier to use? How can you make it even easier? Can you create custom user profiles to help people learn the machine? Consider making the controls field-customizable so the individual user profiles can use different settings or preferences. Also don’t forget users who either don’t speak English, or to whom English is a second language. Can you make the control interface bi-lingual? Or maybe use International Organization for Standardization (ISO) symbols to non-verbally label controls?
Make the Machine Smarter with Automation
With advances in electronic control technology, we have better opportunities than ever to create automated processes. As an example, a hay baler can be built and programmed to lift a hay bale, wrap it in plastic, and place it on a flatbed all with the push of a button. Traditionally, this would have all been done one step at a time by an operator moving the components manually, which would take longer and would be prone to errors. Read more about machine automation here.
Think about ways you can incorporate automated processes into your own machine to help the end user create repeatable machine output. Automation and custom programming can also be used for safety by limiting machine movement to within safe parameters, which can be freely set during the design and programming stage. Read more about machine programming here.
