Enhancing Situational Awareness on the Plant or Factory Floor

Modern human-machine interface (HMI) hardware and connected sensors, controllers, edge devices, and software empower end users in industrial organizations with a multitude of valuable data, information, and actionable insights. But design engineers also understand that all that data and information can distract or overwhelm workers, especially down on the plant or factory floor.

Having to scroll through multiple HMI screens to obtain machine or process status, safety alerts, operating/maintenance instructions, or other basic information can also create confusion, hamper situational awareness, waste time, and lead to human errors that compromise plant production and safety.

In addition, all that often-unused capability comes at a price. Industrial PCs (IPCs), panels, laptops, and handheld digital devices suitable for HMI use on the plant or factory floor are far more costly than PCs intended for home or business use.

As an alternative, Banner Engineering offers the SD50 series of relatively simple and cost-effective programmable status displays designed to clearly communicate performance metrics, machine health, process status, alerts, instructions, or sensor levels. Additionally, Banner offers the K100 series of programmable beacons for applications where 360° visibility is needed.

Information when and where it’s needed

The rugged and compact SD50 programmable status displays (Figure 1) can be easily mounted horizontally or vertically in high-visibility locations throughout a plant or factory floor to effectively communicate status alerts, production information, and operator instructions.

Figure 1: Banner Engineering SD50 programmable status displays combine high-visibility static or scrolling text and multi-color bar graphs and sidebars. (Image source: Banner Engineering)

Housed in durable IP65-rated polycarbonate enclosures, the displays are suitable for many outdoor installations as well as indoor environments where equipment is periodically washed down with low-pressure water. Bright, high-contrast white LEDs provide excellent visibility from distances up to 10 meters and support the presentation of up to 16 static characters or 29 scrolling characters. In addition to text messaging, the SD50 displays incorporate multi-color, high-visibility bar graphs and animations that enable operators to quickly recognize machine status, process conditions, and production updates from across the facility.

The displays support multiple functions:

• Machine outputs can be translated and used to display equipment status, alerts, and maintenance instructions.
• Preconfigured assembly or repair instructions can provide clear sequential guidance to avoid confusion and minimize rework.
• The counter function can display run times, cycle counts, scrap rates, and other key information.
• In sequential production operations, the timer function can display key data points such as runtime and time to completion.
• In discrete manufacturing operations, the timer and counter functions can be combined to display takt time (maximum time to complete a product or task) and other performance metrics.
• The measurement function can display dynamic sensor inputs such as levels, temperatures, flows, distance, or other variables in static or scrolling text and/or multi-color bar graph formats.

Multiple interface options with simple configuration

Banner’s SD50 status displays offer simple integration with PLCs and other host devices or networks, reducing the need to design and maintain custom interfaces. IO-Link, Modbus, and discrete models are available:

• The IO-Link model, SD50P300WKQP, allows dynamic data transmission, remote configuration, and advanced diagnostics directly through an IO-Link master.
• The Modbus model, SD50P300WSQP, uses Modbus RTU serial communications to integrate into RS-485 Modbus industrial networks. Modbus holding registers define display text and indicator behaviors.
• The discrete model, SD50P300WD15QP, uses standard digital high/low wired inputs from a PLC to cycle through up to 15 preconfigured state messages.

To configure the IO-Link and Modbus serial models using Banner’s IO-Link configuration tools, engineers simply choose an operational mode (run/sequence, measurement/level, timer, or counter), indicate the desired display parameters, and then use process signals, pulses, or preset holding registers to send strings and values to update the display. The IO-Link model can also be programmed in standard PLC programming environments.

With the discrete model, engineers can use Banner’s free Pro Editor software and an optional cable to configure colors, animations, and text states, with no coding required.

Matching display modes to application requirements

The SD50 programmable status display provides five different display modes: discrete display control, sequence, counter, measure, and timer, each with multiple states based on preconfigured thresholds. The displays can be configured to show one of seven animations with 14 different color options as well as a unique line of text. Several modes also offer the option to include bar graphs.

For basic discrete display control, engineers can configure up to four states, each controlled by a different input wire. Advanced discrete control, in turn, provides up to 15 unique states. I/O blocks can also be used to control up to three display states.

In the sequence mode, up to 16 different states can be controlled. Signals sent through the assigned input wire or triggered by process data from a PLC change the display to the next state in the sequence.

The counter mode measures the number of input pulses and updates the display status. Counter data can be displayed via a bar graph with associated text to provide context. Four different states can be configured.

In the measure mode, the status display tracks and scales raw sensor measurements and updates based on a pulse-width-modulated (PWM) or pulse-frequency-modulated (PFM) signal from a PLC or other host device. Measured values can be displayed as text and/or in bar graph formats. Associated text can be added to provide context.

In the timer mode, the status display measures how long the appropriate input signal is active and then updates the display. When the timer endpoint is reached, the timer can be automatically reset to start over again. A bar graph can also be used to help visualize the timer progressions. Up to four different states can be configured, with each state triggered when a predefined threshold is reached.

Wireless models enhance installation flexibility and reduce associated costs

The wireless SD50 models can be integrated into 900 MHz or 2.4 GHz wireless networks for configuration and display control (Figure 2). This minimizes the need to install potentially long runs of costly and often vulnerable field wiring to connect the status displays to a PLC or other host device. The wireless architecture supports rapid deployment of displays in locations where traditional HMIs or wired indicators would be impractical, enabling real-time visualization of takt time, machine status, production counts, assembly instructions, equipment health, and other operational data. Multiple SD50 displays can be added to the network as needed, simplifying system expansion while providing operators with clear, high-visibility status information exactly where it is most useful.

Figure 2: Wireless SD50 programmable status displays reduce field wiring costs and integrate easily with Banner and third-party wireless devices and networks. (Image source: Banner Engineering)

Display beacons provide unmistakable visibility where needed

Banner’s K100 programmable display beacons (Figure 3) can be installed on industrial equipment and other assets, both stationary and mobile. The beacons incorporate high-visibility, multi-color lighting and 360° alphanumeric scrolling text, plus audible signals to further enhance worker situational awareness and safety. As with the Banner SD50 status displays, these easy-to-program display beacons feature rugged industrial packaging, making them suitable for use both indoors and outdoors.

Figure 3: Banner K100 programmable display beacons can be mounted on a variety of stationary and mobile assets to enhance situational awareness. (Image source: Banner Engineering)

Conclusion

Banner Engineering’s SD50 status displays deliver clear text, graphics, and operational data where workers need it, while their K100 programmable display beacons extend visibility with 360° text, multicolor lighting, and audible alerts. Together, these rugged, configurable devices improve situational awareness across indoor and outdoor industrial environments.  They provide a cost-effective alternative to traditional HMIs when workers need essential status information, instructions, and alerts without added complexity.