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In my role as a founder actively working within the burgeoning realm of industrial augmented reality (AR), I have had the privilege of witnessing the astonishing pace of developments in how we communicate with machines.
But is it all it's cracked up to be? As an ardent believer in the technology, my enthusiasm may be clouded with bias. Despite significant progress in AR, certain systemic issues continue to pose challenges in its comprehensive integration into operational settings.
Countless failed start-ups and products litter the landscape of the past decade, their ambitious dreams and grandiose promises remaining unfulfilled. Too often, senior executives have been won over by false assurances, only to discover their frontline operators struggling to work with solutions that made life more complicated, not easier.
However, despite the setbacks, I am increasingly convinced (with admitted bias) that the latest surge of AR companies and innovations are poised to deliver on their promise, providing substantial value to frontline operators.
This article aims to explore the developing world of AR, assessing its merits and drawbacks, and providing insights into its potential applications and future trajectory.
A Brief History of Traditional HMI
Understanding the evolution of traditional Human-Machine Interfaces (HMIs) is crucial to appreciating the potential impact of Augmented Reality (AR) in the industrial arena.
From manual controls such as switches and dials to the complexity of control panels, industrial automation has come a long way. The introduction of computer-based control systems in the 1960s marked a significant step forward, enabling operators to manage processes from a single terminal, thereby increasing productivity and reducing errors. However, these systems were basic and text-oriented.
The 1980s and 1990s saw the advent of graphical HMIs, which offered user-friendly interfaces, real-time data visualisation, and trend analysis capabilities. During this period, pushbuttons, lights, dial gauges, annunciators, and tubes also emerged as integral components of control systems.
By the mid-1990s, control room operations were dominated by proprietary man-machine interfaces (MMIs), with Personal Computers (PCs) beginning to permeate manufacturing setups. The HMI landscape was gradually shifting from hardware to software, a shift driven by companies like Wonderware.
In the late 1990s, Ethernet connectivity and improvements in HMI software and control PC specifications within Distributed Control Systems (DCS) were introduced. The focus of the new millennium was on advancing display technology, touchscreen evolution, and a move towards thin client architecture.
The period post-2010 brought video technologies and multitouch capabilities into the mix. Driven by consumer demands and a technology-savvy workforce, mobile devices began to take on HMI functions. Today, we stand at a critical juncture, contemplating the past journey and future potential of traditional HMIs and the disruptive force AR might represent.
The Rise of AR in HMI
Augmented Reality (AR), with its promise to revolutionise the HMI space, is emerging as a potential game changer. Its inherent ability to blend the digital and physical worlds in ways that traditional HMIs cannot, makes it an exciting prospect.
AR's potential in the industrial sector is significant. Operators are no longer tethered to static screens but can access real-time data overlays right in their field of view. Imagine an operator approaching a machine, instantly presented with critical data – temperature, pressure, efficiency, maintenance history – superimposed onto the machine itself. The control and monitoring process becomes more intuitive and efficient.
AR can also help bridge the gap between retiring experienced operators and an incoming workforce with less technical expertise. For instance, a novice operator alerted about a machine failure can use AR software to guide them through the troubleshooting and repair process step-by-step.
The costs of integrating AR with existing systems are also considerably lower compared to large-scale HMI installations. A typical AR implementation involves connecting the existing facility data system (usually a SCADA system) to the AR system, scanning the environment using a mobile device or headset, and linking 3D representations of data to the corresponding machinery. All this can be achieved in a matter of days, if not hours and doesn’t take a specialised expert to do.
The Downsides of AR in HMI
AR in HMI is not without its challenges. User acceptance, a potential information overload, and the limited availability of suitable headsets represent notable obstacles.
While traditional HMIs offer familiarity and comfort to operators, AR HMIs have yet to establish this level of acceptance. Training personnel to effectively use AR HMIs adds to the complexity and expense. Also, the risk of overwhelming users with too much information can negate the benefits of increased visibility and control.
The choice of viewing devices is another concern. Initially, our excitement about Microsoft’s Hololens quickly turned to disappointment due to its heavy weight, limited field of view, slow startup speed, and prohibitive cost. We shifted our focus to mobile phones, which are becoming increasingly better equipped for viewing AR content. However, using a phone while troubleshooting machinery can be cumbersome and unsafe.
But, things are changing. Newer headsets like Apple’s Vision Pro, or Meta’s Quest Pro have solved many of the problems which plagued the Hololens. Faster processors, more efficient power usage, and improved display technology make these new devices more lightweight, comfortable, and less expensive, and In my opinion, are just a few years out before becoming commonplace in facilities throughout the world.
Will AR Replace Traditional HMI?
While it is too early to predict that AR will completely replace traditional HMIs, the potential is undeniable. Despite current challenges, it is important to remember that these are merely stepping stones in a journey of progress. When considering the potential benefits – more intuitive interactions with machinery, cost savings, improved training and maintenance protocols – it is clear that AR holds a promising future in the HMI space.
Only time will decide if and when AR will disrupt traditional HMI. But considering the ongoing advancements in this field, it seems less a question of ‘if' and more of ‘when'.
