Choosing the Right Industrial Computer Monitors for Manufacturing Environments

Introduction

Industrial computer monitors are specialised display systems designed for mission-critical applications in harsh manufacturing and processing environments. Selecting the optimal industrial monitor requires understanding key performance factors, display technologies, connectivity, mounting options and environmental ratings. This comprehensive guide provides expert insights on choosing the best industrial computer monitor for reliability, safety and productivity.

Key Differences Between Consumer and Industrial Monitors

Industrial monitors are engineered for manufacturing and factory environments, while consumer displays are designed for homes or offices. Here are some of the main differences:

Temperature – Operating temperature ranges from -4°F to 140°F+ allow reliable performance in extreme cold and heat like that found in outdoor plants or manufacturing lines.

Connectivity – Interfaces like serial, Gigabit Ethernet, USB and optional plug-in cards enable seamless connection to industrial PCs, PLCs, sensors, cameras and other equipment.

Hazardous Ratings – Monitor enclosures carry hazardous location certifications for deploying safely where combustible dust and flammable gases/vapours may be present.

Lifetime – Components and construction optimised for 100,000+ hours of uninterrupted operation for over a decade.

With this understanding of how industrial monitors fundamentally differ from consumer-grade displays, let’s examine key selection criteria in detail.

Key Selection Criteria for Industrial Monitors

Choosing the best industrial monitor requires careful consideration of performance, durability, connectivity, and environmental factors. Key criteria include:

Visual Performance

Larger display sizes from 15” to 24”+ provide ample workspace while Full HD (1920 x 1080) or higher resolution delivers crystal clear imaging and fine details. Look for:

Panel Size – 15”, 17”, 19”, 21”, 24” and larger sizes available depending on application.

Resolution – Full HD or QHD 2560 x 1440 recommended minimum. 4K is also available.

Brightness – 250-1000 nits for clarity in variable lighting. Enhanced brightness improves sunlight viewability.

Contrast Ratio – 800:1, 1000:1, 1500:1+ for sharp imagery and text.

Viewing Angles – 178°/178° IPS viewing angles prevent washout when viewed off-centre.

Also ensure the display has adequate controls for brightness, contrast and calibration to tune for optimal viewing.

Touchscreen Technologies

Touchscreens enhance visualisation by allowing direct on-screen interaction. Key technologies include:

Resistive Touch – Durable glass overlay pressed to make contact. Can be used with gloves. More affordable option.

Capacitive Touch – Senses touch through glass via electrical properties of the user’s body. Supports multi-touch gestures. High image clarity.

Surface Acoustic Wave – Most advanced and accurate touch recognition. Unaffected by contaminants like dirt, oil or moisture.

Look for touch accuracy within 2-3mm for precise interface control, even when wearing gloves.

Ruggedness and Environmental Protection

Monitor enclosures must protect internal components from dust, fluids and impacts:

• IP Rating – IP54 minimum, but IP65 or IP66 provides complete protection against dust ingress and high-pressure water jets.

• IK Rating – IK08 is minimum against mechanical impacts. IK10 can withstand up to 20 joules of impact force.

• MIL-STD or IEC Certified – 3rd party testing ensures vibration, shock and drop resistance for years of trouble-free operation.

• Operating Temperature – Look for wide operating ranges from -4°F to 140°F for industrial heat and sub-zero cold.

Also, ensure effective thermal design for fanless cooling. Vented monitors can quickly clog from airborne contaminants.

Mounting Requirements

Common mounting options include:

Panel Mount – Secure, flush-mounted built-in installation. Provides stationary usage.

VESA Mount – Utilize arms or stands for flexible positioning and viewing angles.

Rack Mount – 19” rack slides to install in cabinets alongside other equipment. Enables dense deployment.

Pedestal Mount – Floor-mounted pedestal stand brings monitor to proper height. Allows mobility.

Evaluate available space and anticipated adjustment needs when selecting the mounting type.

Connectivity for Industrial Networks

Connectivity enables vital integration with other machines and automation:

Video Inputs – VGA, HDMI, DVI and DisplayPort allow interfacing to diverse computing platforms from PLCs to PCs.

Network Ports – Ethernet, and WiFi provide network connectivity for accessing data, remote control and central management.

USB Ports – Multi-USB options let you interface with cameras, storage drives, printers and other peripherals.

Serial – Legacy RS-232, RS-422 and RS-485 serial allows connecting to older industrial systems and devices.

Modular Expansion – Some monitors offer slots to install communication cards for specialised protocols like PROFIBUS, CanBus, EtherCAT and more.

Carefully assess connectivity needs for integration into existing or planned industrial control systems.

Hazardous Location Ratings

For deployment in areas with potentially explosive gases, vapours or combustible dust, the monitor must carry hazardous ratings like:

UL/cUL Class I Div 2 – Approved for hazardous locations with certain atmospheric gases/vapours present. Rating defines approved deployment conditions.

ATEX/IECEx – Certified for installation in ATEX/IECEx Zone 2/22 areas with continuous combustible dust or accidental gas or vapour releases.

Marine Certifications - Ex ratings for saltwater/spray resistance. Necessary for offshore applications.

Always verify hazardous ratings match the anticipated industrial risks before deployment. Non-rated monitors can seriously endanger facilities and workers if improperly installed in classified areas.

Industrial Monitors vs. HMIs

In addition to industrial monitors, another specialised display category used extensively in manufacturing is the Human-Machine Interface (HMI). Both serve critical visualisation functions, but have some distinct differences:

• Industrial Monitors – Display video/data from connected computers and machines. More limited control capabilities.

• HMIs – All-in-one interface with integrated PC computing. Allows complete control of processes through touch input.

Key Differences:

• Computing Power - HMIs have powerful integrated controllers, while monitors connect to external PCs.

• Interactivity - HMIs allow complete interactive process control and data input using touch. Monitors have more limited touch capabilities.

• Software - HMIs run dedicated HMI software for visualisation and control. Monitors display video from external sources.

• Connectivity - HMIs support extensive industrial communication protocols. Monitors offer more generic video/data inputs.

Industries and Use Cases:

• Manufacturing: HMI touch panels installed at each workstation, machine and assembly line to display critical data and allow operators to control equipment.

• Factory Automation: HMIs used extensively for visualisation, control and monitoring of industrial control systems, PLCs and robotic elements. Critical for automated sequences.

• Process Control: Both HMIs and industrial monitors are used in control rooms and process monitoring applications to display key parameters and video feeds.

So in summary, HMIs provide fully integrated interface solutions with computing power and control software built-in. Industrial monitors offer simpler visualisation and touch capabilities working in conjunction with a separate industrial PC. Manufacturing and process industries utilise both technologies in complementary roles.

Leading Industrial Monitor Manufacturers

Reputable vendors offering rugged displays engineered for industrial environments include:

Pepperl+Fuchs – Robust touchscreen HMIs purpose-built for hazardous locations including ATEX/IECEx Zone 1/21 classified areas. High-performance integrated computing.

Hope Industrial – Feature-rich industrial monitors with high-definition, high-brightness LED-backlit displays. Stainless steel NEMA 4X enclosures. UL/cUL Class I Div 2 models.

Advantech – Broad range of panel PCs, open frame monitors and marine displays rated to IP66 with wide -4°F to 140°F operation. MIL-STD and IK-rated construction.

Siemens – Leading supplier of Simatic industrial monitors for visualisation and control. Rugged panels and HMIs engineered for manufacturing automation and process industries.

Rockwell Automation – Allen-Bradley PanelView HMIs and monitors specifically designed for industrial automation systems. UL hazardous location approved.

Red Lion – Rugged industrial displays with touchscreen, sunlight viewable and wide temperature range options. PROFIBUS, Ethernet/IP and Modbus enabled.

Winmate – Rugged panel PCs and open frame monitors with high-brightness displays. IP65 water and dust protection. MIL-STD-461F certified for EMI/RFI.

GE Automation – GE Monitouch HMI and display lineup provides rugged visualisation solutions for industrial control and SCADA systems.

Reputable industrial monitor vendors offer rugged displays purpose-built and certified for challenging environments. Look for models aligned to your specific size, performance, sealing and hazardous rating requirements.

Conclusion

Selecting the optimal industrial computer monitor requires careful evaluation of performance specifications, ruggedness, connectivity and environmental sealing to match your operating conditions. Larger panel sizes, Full HD resolution, capacitive multi-touch, IP65 hazardous ratings and flexible mounting are all worth the investment to maximize utility.

Leading manufacturers like Pepperl+Fuchs, Hope Industrial, Advantech and Siemens offer a diverse range of industrial displays purpose-built to withstand the harshest manufacturing environments. Look for hazardous location certifications, wide operating temperature ranges and IK-rated construction suitable for your needs.

Investing in a properly specified industrial monitor pays dividends through drastically extended lifetimes, reduced downtime, and reliable 24/7 performance for over a decade. This guarantees the visual insights operators need to work efficiently, and safely and optimise production.

At XY Automation, we are leading suppliers of industrial automation and control system components, including a wide range of rugged industrial computer monitors and HMI solutions. We can provide the ideal display for your operating environment.

Our dedicated account managers will work with you to understand your visualisation, control, and hazardous rating requirements, and identify the optimal industrial monitors or HMIs to maximise productivity.

We supply all major brands and maintain extensive inventories of hard-to-find parts, getting you fast access at competitive prices. Contact us today to get a competitive quote from one of our experienced account managers.