Process Visualization (Level 3)

Understand the thesis of process visualization as a two-way dialogue between operator and machine, where the system communicates current activity, efficiency, and alarms.

Compare a dedicated HDMI panel with a PC-based interface, weighing proximity to the machine, data logging, trending, and reports against PC flexibility, distance, and cost.

A human machine interface is a device or application that translates machine signals into pictures, words, and numbers, enabling the operator to monitor, control, and configure without complex ladder logic.

Explore how scada provides a high-level supervisory view across multiple machines, contrasts with hmi, and uses data acquisition, big data, and tags through a one-to-many relationship to drive insights.

Explore the differences between HMI and SCADA: HMI delivers detailed, low-level control for a single machine, while SCADA provides high-level, multi-machine oversight with stored data on a server.

Explore the similarities between HMI and SCADA systems, including shared protocols, interfaces, and development platforms, and learn that both achieve the same visualization and control tasks with a common skillset.

Compare user interface and user experience to show that speed and clarity for the operator trump flashy design, guiding practical, multi-screen workflows.

Explore three screen types—data displays, diagram displays, and illustrated displays—that present raw values, system schematics, and graphical representations to support efficient, intuitive operation.

Learn to set up and run a virtual machine with VMware Player, enable hardware virtualization, allocate RAM, and install VMware Tools for file sharing between host and virtual machine.

Install and explore Wonderware (InduSoft Web Studio), a robust HMI/SCADA platform with a wide driver set and flexible controls for process visualization and data acquisition.

Install Visual Studio Community Edition as administrator and complete the setup. Open the AdvancedHMI project, load the .sln file, build, and drag controls from the toolbox onto the form.

install and set up Seymore to create HDMI programs for the animation direct brand panels, then open the development environment and start new projects with push buttons and switches.

Install EZware 5000 with admin rights, accepting defaults and a standard location. Open Easy Builder 5000 to a 1024 by 768 HDMI design screen with a grid and basic tools.

Install and set up com0com, a virtual com port pair creator; despite installation errors, the software works, and you configure a port pair to emulate serial connections.

Install and configure SQL Server Management Studio, run as administrator, accept terms, disable updates, and complete the setup before the restart, then continue to learn how SQL Server works.

Install and configure sql server express with management studio, create a default instance, and store and retrieve data from your program for data logging and data acquisition.

Explore how OPC servers act as a translator between HDMI devices and PLCCs using a standardized protocol, enabling communication across diverse hardware and software in automation.

Compare three interface cables—serial, ethernet (cat 5 with possible direct or through a switch), and proprietary—covering reliability, speed, network needs, and when to favor ethernet over specialized cables.

explore how drivers implement defined protocols that let hdmi and plc communicate through instructions, data formats, and signals, and how opc servers enable cross-device data exchange.

Explore a real-world process visualization with a programmable logic controller driven water filtration system, featuring P&ID interpretation, sensors, valves, pump control, and automatic backwash based on differential pressure.

Examine the PLC program structure with ladder-based IO setup, alarm logic, backwash sequencing, tank level control, and data logging across hand mode and automatic mode.

Operate a system simulation to start a tank, pump, and filter in auto mode, watch differential pressure rise, and trigger backwash at five psi while meters count runs.

Explore the automation direct HDMI design suite development environment, configuring panel models, ports, and tag databases, while using the object palette to drag controls onto screens and simulate your app.

Create a new project in Seymore, choose the 15 inch panel and a driver with PLCC protocol, and verify the screen is ready to develop in about 20 seconds.

Configure communications with panel manager by assigning com ports for ethernet, serial, and HDMI, using on-screen graphics to identify ports and enable flexible IP, protocol, and PC compatibility.

Set up tags as memory addresses in the HDMI environment, defining bit, integer, and float tags for device 001 PLCC, then filter to view only device tags.

Create and distinguish three screens, wire navigation with a screen change push button and a screen selector, rename screens to show name or number, and test navigation with simulate.

Explore basic controls in Seymour: use pushbuttons as momentary signals, link tags, and configure numeric entry from 0 to 255 with 3 digits, plus indicators and sliders.

Explore basic displays by linking digital and analog controls to a numeric display and indicator, simulate passing 0–100 values through the system, and visualize bits and numbers.

Explore drawing tools and animations by building a tank visualization with shapes, a water level fill, and a slider controlling animation size and rotation.

Configure Seymour security by creating eight accounts with an approved group and a password like 1 2 3, then apply security to controls via the password tab on numeric entries.

Set alarms as events in the event manager by linking a tag to a status bit and a trigger message like you've just tripped the alarm.

Explore the factory talk view studio environment and interface, drawing tools, and libraries for building animated process visuals. Learn to simulate, test, save, and transfer applications, noting Windows compatibility issues.

Create a new application in factory talk view studio, name it to start, and back it up with the application manager as a mer file for transfer to another computer.

Configure communications by adding a new server, selecting an OPC data server with RSS links, and linking it to a local emulate setup to access project data.

Define and configure tags in process visualization by creating digital and analogue tags, mapping them to the PC server, and preparing control tags.

Navigate between screens using go to and return to, save screen two (s2) and the main screen, and configure the display navigation with a display lists selector.

Explore how to implement basic controls in process visualization, focusing on momentary push buttons, tag connections, state feedback, and numeric and string inputs to wire digital and analog signals.

Design two-state indicators to show running or stopped status with red and green colors, connect to offline OPC tags, and format numeric displays in Factory Talk View Studio.

Learn drawing tools and digital animations by placing a pump and circle, using tag P1 to toggle green or red, and exploring visibility and rotation in factory talk view studio.

Create a manager user, assign A–P security codes in runtime security, and enforce login to control access to screens and protect secured content.

Create and manage an alarms screen with a live alarm list, acknowledge, silence, reset, and history; configure a low flow alarm triggered by a tag with a pop-up.

Explore the advanced HMI development environment, focusing on the main window, toolbox, and properties to build screens with controls and drivers, and evaluate its free value versus production limitations.

Configure PLCC communications by selecting the HDMI driver, connecting com4 with auto baud and CRC, and enabling Modbus and OPC to talk to emulate.

Design and configure basic on-screen controls, including a start button with a PLCC address B-3:3/3 and a write-to value, and use a PLCC address keypad to adjust a tank level.

Learn to display values with bits, text, images, and a run indicator, configure start and stop buttons, and visualize a tank level with a blue graphic from 0 to 100.