Application of Industrial Panel PC in Industrial HMI: How to Replace Traditional Button Control Panels?

Driven by the wave of Industry 4.0, the limitations of traditional button control panels are becoming increasingly prominent. Issues such as single functionality, fixed layouts, inability to provide real-time data feedback, and difficulty in integrating multi-protocol devices are emerging as "invisible bottlenecks" that restrict the improvement of production efficiency. Leveraging its core capabilities of multi-protocol integration, edge computing, and intelligent interaction, industrial panel PCs are redefining the boundaries of industrial human-machine interaction (HMI). This article will delve into how industrial panel PCs can become the "ultimate replacements" for traditional control panels from four dimensions: technological evolution, scenario pain points, replacement solutions, and implementation paths, providing enterprises with actionable upgrade plans.

1. Four Major Pain Points of Traditional Button Control Panels: Why Must They Be Replaced?

1.1 Protocol Barriers: The "Language Barrier" in Device Interconnection

Traditional control panels typically support only a single protocol (e.g., Modbus RTU), while modern industrial sites often feature dozens of devices such as PLCs, sensors, and robots, with over 100 types of protocols. For instance, an automotive parts factory once had to develop three separate interfaces for different devices due to protocol incompatibility, resulting in a data collection completeness rate of less than 65% and a deployment period of up to three days. This "language barrier" directly restricts equipment collaboration efficiency.

1.2 Fixed Functionality: Inability to Adapt to Flexible Production Needs

The button layout and functional logic of traditional panels need to be solidified in advance. If production processes need to be adjusted (e.g., adding an inspection step), the hardware circuitry and panel layout must be redesigned. A 3C product assembly line once had to replace its entire control panel due to product iteration, leading to a downtime of 12 hours and annual losses exceeding one million yuan.

1.3 Data Silos: Lack of Real-Time Analysis and Decision-Making Capabilities

Traditional panels can only display basic statuses (e.g., running/stopped) and cannot perform real-time analysis of critical parameters such as temperature and vibration. A blast furnace monitoring project at a steel plant revealed that manual inspection-based fault response times were as long as five minutes, while edge computing could reduce response times to eight seconds, preventing major production accidents.

1.4 High Maintenance Costs: Hardware Aging and Spare Parts Dependency

The mechanical buttons on traditional panels typically have a lifespan of 500,000 cycles and need to be replaced annually in high-frequency usage scenarios, with high spare parts inventory costs. A chemical park suffered annual losses of two million yuan due to unplanned downtime caused by panel failures.

2. Core Advantages of Industrial Panel PCs: How Do They Solve Traditional Pain Points?

2.1 Protocol Breakthrough: Multi-Protocol Integration and Automatic Conversion

Industrial panel PCs are equipped with industrial protocol stacks that support over 100 protocols, including Modbus TCP, CANopen, and OPC UA, and can simultaneously connect to more than 200 PLCs and 500 sensors. For example, the USR-SH800 industrial panel PC reduced device interface development time from three days to two hours through its protocol conversion function, improving production line data collection completeness to 98%.

2.2 Flexible Interaction: From "Fixed Buttons" to "Dynamic Interfaces"

All-in-one screens adopt touchscreens and configuration software designs, supporting functions such as logical split screens, multi-screen interaction, and mobile projection. For example:

• Logical Split Screens: Divide a single screen into multiple areas to display equipment parameters, quality inspection data, and alarm information separately.
• Mobile Projection: Project the content of the all-in-one screen onto a mobile phone by scanning a QR code, creating a "monitoring center in your pocket."
• AR Augmented Display: In wind farm operations and maintenance, overlay real-time parameters and historical maintenance records of wind turbines through AR glasses.
  An automotive parts factory built a production line digital twin system using the USR-SH800, with the main screen displaying a 3D model mapping equipment status, the secondary screen showing quality inspection data, and the mobile end providing maintenance guides, reducing mold change time by 35% and improving overall equipment efficiency (OEE) by 18%.

2.3 Edge Intelligence: Local Decision-Making and Real-Time Response

All-in-one screens integrate edge computing platforms that can perform data cleaning, real-time analysis, and linkage control locally. For example:

• Data Cleaning: Filter out more than 90% of invalid data (e.g., duplicates, outliers).
• Real-Time Analysis: Identify equipment anomalies through threshold comparisons and trend prediction algorithms.
• Linkage Control: Automatically activate cooling fans when temperatures exceed limits.
  A blast furnace monitoring project at a steel plant showed that edge computing reduced data transmission volume by 75%, shortened fault response times from five minutes to eight seconds, and prevented an accident that could have halted iron production.

2.4 AI Empowerment: From "Passive Response" to "Proactive Prevention"

All-in-one screens support the deployment of lightweight AI models, enabling functions such as equipment health assessment and process parameter optimization. For example:

• Equipment Health Assessment: Predict the remaining lifespan of equipment using vibration and temperature data.
• Process Parameter Optimization: Analyze historical data to recommend optimal production parameter combinations.
  A 3C product assembly line project showed that AI empowerment reduced product defect rates from 1.2% to 0.3%, saving over two million yuan in annual quality costs.

3. USR-SH800 Industrial Panel PC: The Ideal Choice for Industrial HMI Upgrades

3.1 Hardware Configuration: Balancing Performance and Reliability

• Processor: RK3568 chip, 4-core 64-bit ARM architecture, 2.0GHz clock speed, supporting smooth multitasking.
• Memory: 4GB RAM + 32GB ROM, meeting complex application requirements.
• Screen: 10.1-inch capacitive touchscreen, 8ms response time, supporting glove operation.
• Interfaces: 2 RS485 ports, 2 RS232 ports, 2 Ethernet ports, 2 USB ports, compatible with various industrial equipment.
• Installation Methods: Supports rail mounting (saving space) and bracket mounting (stable and reliable).

3.2 Software Ecosystem: Open and Flexible Secondary Development

• Operating System: Linux Ubuntu 20.04, supporting desktop operations and easy installation of development tools.
• Edge Computing: Built-in WukongEdge application, integrating data collection, computation, reporting, and configuration functions.
• AI Support: CPU integrated with 1.0 TOPS NPU, supporting frameworks such as TensorFlow Lite, achieving equipment fault prediction accuracy exceeding 92%.
• Low-Code Development: Provides Node-RED visual tools, enabling HMI development and deployment within 72 hours.

3.3 Typical Application Scenarios: From Discrete Manufacturing to Process Industries

• Smart Manufacturing: Build production line digital twins, real-time mapping of equipment status, and optimize production processes.
• Smart Energy: Implement grid demand response, dynamically adjust electricity usage strategies, and improve renewable energy consumption rates.
• Remote Operations and Maintenance: Guide on-site personnel to complete complex maintenance tasks through AR + voice interaction, reducing expert travel by 60%.

4. Upgrade Path: How to Smoothly Transition from Traditional Panels to Industrial Panel PCs?

4.1 Needs Assessment: Clarify Upgrade Objectives

• Functional Requirements: Whether multi-protocol support, edge computing, AI prediction, etc., are needed.
• Scenario Requirements: Whether extreme environments such as high temperatures, high humidity, and strong electromagnetic interference are involved.
• Budget Requirements: Balancing hardware costs, development costs, and maintenance costs.

4.2 Solution Selection: Match Scenario Requirements

• Lightweight Scenarios: Choose a basic version of the all-in-one screen, supporting protocol conversion and basic configuration.
• Complex Scenarios: Choose a high-end version of the all-in-one screen, integrating edge computing and AI functions.
• Customized Scenarios: Develop proprietary applications based on open API interfaces (e.g., integration with ERP/MES systems).

4.3 Deployment Implementation: Progress in Stages

• Pilot Phase: Select 1-2 production lines for pilot testing to verify the feasibility of the solution.
• Promotion Phase: Optimize the solution based on pilot results and gradually expand it to the entire factory.
• Optimization Phase: Continuously collect data and iterate AI models and interaction logic.

4.4 Operations and Maintenance Support: Ensure Long-Term Stable Operation

• Remote Management: Achieve parameter configuration, firmware upgrades, and fault diagnosis through cloud platforms.
• Local Maintenance: Provide 7x24-hour technical support to quickly respond to on-site issues.
• Training Services: Conduct specialized training for operators and maintenance personnel to shorten the learning curve.

5. Future Trends: How Will Industrial Panel PCs Evolve?

5.1 Display Technology Upgrades

Mini LED backlighting technology improves contrast to 10,000:1 and supports HDR10 display standards, maintaining clear visibility in bright environments.

5.2 Interaction Method Innovations

Integrate ToF sensors for gesture control and bone conduction technology for silent voice interaction, adapting to noisy environments.

5.3 Intelligent Capability Expansion

Built-in large language models (LLMs) support natural language queries and control (e.g., "Retrieve equipment fault records from last Wednesday").

6. Upgrade to Industrial Panel PCs and Seize the Opportunity for Industrial Intelligence

Driven by the dual goals of "carbon peaking and carbon neutrality" and smart manufacturing, industrial panel PCs have become an inevitable choice for industrial HMI upgrades. They not only address the protocol barriers, fixed functionality, and data silos of traditional button control panels but also build enterprises an "real-time perception-local decision-making-remote collaboration" intelligent production system through edge computing, AI empowerment, and flexible interaction technologies.

Click the button to engage in one-on-one communication with PUSR experts, obtain a customized upgrade plan for the USR-SH800 industrial panel PC, and embark on your journey of industrial intelligence transformation!