Maximising Efficiency with Integrated HMI and PLC Units for Automation Tasks
- tass peters
- Jan 13
- 4 min read
Automation projects often face challenges like limited panel space, complex wiring, and the need for seamless control and monitoring. Integrated HMI and PLC units, such as those offered by ProSense, address these issues by combining the operator interface and control logic into a single device. This approach simplifies design, reduces costs, and improves system performance for small to medium automation tasks.
This post explores how integrated HMI + PLC units work, their key features, and practical benefits. It also highlights how ProSense’s solutions support efficient automation with advanced connectivity and data visualisation.
What Are Integrated HMI and PLC Units?
Traditionally, automation systems use separate devices for the Human Machine Interface (HMI) and the Programmable Logic Controller (PLC). The HMI provides the operator interface, while the PLC handles control logic and I/O management. Integrated HMI + PLC units combine these two functions into one compact device.
This integration means the touchscreen interface and control logic share the same hardware platform. The result is a streamlined system that requires less wiring and panel space, making it ideal for smaller automation setups or where space is at a premium.
Key Features of Integrated HMI + PLC Units
Integrated units like those from ProSense come with several important features that support efficient automation:
Compact Design
One device handles both HMI and PLC functions, reducing the need for multiple components. This lowers installation costs and frees up panel space.
Intuitive Touchscreen Interface
Sizes range from 4.3 inches to 10.1 inches, providing clear, user-friendly control. Operators can easily monitor processes and adjust settings directly on the screen.
Versatile I/O Options
Built-in digital inputs and outputs (DI/DO) support basic control tasks. Optional analog I/O modules allow connection to sensors measuring temperature, voltage, or other variables.
Advanced Control Functions
Support for high-speed counting, pulse outputs, PID control, and interpolation enables precise and complex automation tasks.
Multiple Connectivity Options
USB ports simplify programming. Communication interfaces include RS232, optional RS485, Ethernet, and Wi-Fi, allowing flexible network integration.
Standard Protocol Support
Compatibility with Modbus and other protocols ensures easy connection to SCADA systems and other networked devices.
Cloud Integration
ProSense’s ProSight platform offers cloud-based data visualization, remote access, and analytics, enhancing monitoring and decision-making.
Integrated HMI and PLC unit installed in a compact industrial control panel
Benefits of Using Integrated HMI + PLC Units in Automation
Space and Cost Savings
Combining HMI and PLC into one device reduces the number of components needed. This means less wiring, fewer connectors, and smaller control cabinets. For example, a small packaging line can use a single ProSense unit instead of separate HMI and PLC devices, cutting hardware costs by up to 30%.
Simplified Engineering and Maintenance
With one device to program and maintain, engineers spend less time on configuration and troubleshooting. ProSense units support programming with GX Works2 software, a familiar environment for many automation professionals. This reduces the learning curve and speeds up project delivery.
Improved Operator Experience
Touchscreen interfaces provide clear, real-time data visualization and control. Operators can quickly respond to alarms, adjust parameters, and monitor system status without navigating complex menus or multiple devices.
Flexible Connectivity and Integration
ProSense units support common communication protocols like Modbus and Ethernet, allowing easy integration with existing SCADA systems or factory networks. The optional Wi-Fi feature enables wireless monitoring and control, useful for remote or hard-to-reach installations.
Advanced Control Capabilities
High-speed counting and pulse output functions support applications such as conveyor speed control or batch counting. PID control allows precise regulation of temperature, pressure, or flow, improving product quality and process stability.
Practical Examples of Integrated HMI + PLC Units in Action
Example 1: Small Food Processing Line
A small food processing plant uses a ProSense integrated unit to control conveyor belts, temperature sensors, and packaging machines. The compact design fits into a limited control cabinet space. Operators use the touchscreen to monitor production speed and adjust temperature setpoints without stopping the line.
Example 2: Water Treatment Plant
In a water treatment facility, a ProSense unit manages pumps, valves, and chemical dosing systems. The built-in analog inputs connect to pH and turbidity sensors. Remote monitoring through ProSight cloud platform allows technicians to check system status and receive alerts from anywhere.
Touchscreen interface of integrated HMI and PLC unit displaying real-time process data
How to Choose the Right Integrated HMI + PLC Unit
When selecting an integrated unit, consider the following:
Screen Size
Choose a touchscreen size that fits your operator needs and panel space. Smaller screens suit simple tasks, while larger screens provide more detailed visualization.
I/O Requirements
Assess the number and type of inputs and outputs needed. Ensure the unit supports the sensors and actuators in your system.
Communication Needs
Verify the supported protocols and interfaces match your network setup. Ethernet and Wi-Fi options provide more flexibility.
Control Functions
Confirm the unit can handle your control logic complexity, including high-speed counting or PID loops if required.
Software Compatibility
Use programming software that your team is comfortable with to reduce training time.
Final Thoughts on Integrated HMI + PLC Units
Integrated HMI and PLC units offer a practical solution for small to medium automation projects. By combining control and operator interface in one device, they reduce costs, save space, and simplify system design. ProSense’s range of units supports versatile I/O, advanced control functions, and multiple communication options, making them suitable for diverse applications.
