The land doesn’t belong to me. It’s only on loan from my children.” This wisdom from his grandfather, a farmer, still drives Karl Lehnhoff today. Accordingly, he is fascinated by the concept of the All Electric Society, which he has been advancing for more than two years as Director of the Industrial, Scientific, and Medical market segment at EBV. He sees it as an opportunity to create a cleaner and better world – not only for today’s generation but, above all, for future generations.

How realistic do you think it is that the All Electric Society will come to pass?

Karl Lehnhoff: It’s quite realistic. From a technological point of view, all the necessary solutions are available today. We may need to work on the economics and political conditions. In the European Union, we already have several regulations for more sustainability, and now we need to translate them into national laws.

What will it take to convince consumers?

K. L.: Consumers are aware of the environmental point of view, but we need to explain what needs to change and how it needs to change. And what the economic impact would be. Then it will be easier to convince consumers. This is something our politicians have to do. Consumers are not stupid. If you explain it in the right way, they will understand.

What technologies are still needed to make an All Electric Society a reality?

K. L.: We more or less have all the technology. What we need to do is combine renewable energy sources with energy storage solutions. The backbone of all this is digitalisation. You can call it IoT, but at the end of the day, it is communication between the different devices of the energy ecosystem.

What is the best way to bring the many different components and areas of the All Electric Society together?

K. L.: It requires a systematic and integrated approach. At EBV, we can help with this on both a system and technology level. We support our customers in selecting components and integrating individual solutions into a complete system. We are members of various associations to identify technology trends early and understand the future paths.

And what’s the role of electronics in the realisation of the All Electric Society?

K. L.: Electronics are at the heart of many solutions for the All Electric Society. Think of power electronics, all the intelligence to control the systems, and communication interfaces. Hardware and software make monitoring, control, and integration possible.

Sector coupling is a key part of the All Electric Society, where we’re connecting energy with industry, transportation, and buildings. These are all areas that EBV is involved in. Does this interconnection make your job easier?

K. L.: That was one of the aims of our structure. We have a much deeper knowledge of the market and can support the customer much better. On the other hand, we have technology segments, so we can support the customer with in-depth knowledge of the many specialised technologies. With this vertical approach between market and technology, we can ensure that our customers’ innovative products have the latest technology and are ready for the latest market trends.

What role does energy efficiency play in all these considerations? What can the semiconductor industry contribute?

K. L.: Energy efficiency is very important – energy that you don’t waste, you don’t have to generate. From a technology perspective, this is the driver for wide-bandgap semiconductors. Silicon carbide and gallium nitride transistors will increase efficiency, reduce losses, and therefore gain market share.

However, another interesting technical development is taking place: the shift from an AC to a DC grid. In the past, electricity was generated, distributed, and used in alternating current. But today, photovoltaic systems generate direct current and feed it into the grid. With the existing grid, we have to convert the power to AC for transport, and then convert it back to DC for use. Does that make sense? No, it does not! Especially if you include the storage system, which typically works with DC. A DC grid reduces the losses caused by converting energy between AC and DC and vice versa.

How do you see the world in 20 to 30 years when the concept of the All Electric Society has been successfully implemented?

K. L.: The world will be a much cleaner place with less CO₂ in the atmosphere. It will be more efficient, and I think it will be more technology-based. Maybe we will discover additional renewable energy sources. Our lifestyle will be much more sustainable and environmentally friendly. And perhaps we will have moved Earth Overshoot Day from spring to autumn.

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The energy transition poses significant challenges for power grids. Today, electricity flows in one direction from the power plant to the transmission network and then to the consumer. In the networks required for an All Electric Society, electricity flows from hundreds of thousands of small, decentralised plants in all directions. As photovoltaic or wind power plants feed electricity irregularly in terms of time and quantity into all voltage levels, the load on the distribution networks fluctuates considerably. This new type of energy distribution heavily burdens the distribution network, making the infrastructure increasingly inefficient. Simultaneously, capacities must be expanded to reliably supply the growing number of electricity consumers.

“To be clear: Our current power grid is not designed for this. It is not energy-transition capable,” emphasises Wolfgang Weber, Chairman of the Management Board of the German Electrical and Digital Industry Association ZVEI. The association calls for intelligence to be incorporated into the system in addition to physical expansion.

Smart Grid: The Intelligent Power Grid of the Future

Smart grids coordinate electricity generation, distribution, and storage by continuously collecting and analysing data from IoT-enabled sensors and devices. This allows optimal control and utilisation of power grids, contributing to stable and efficient energy supply. These smart grids enable two-way communication and the return of excess electricity to the grid through smart meters. The increasing use of energy management devices and consumer involvement helps providers reduce peak demand and delay infrastructure modernisation.

Smart Meters: Intelligent Meters for Consumers and Prosumers

On the consumer side, smart meters are the core element of future energy supply networks. These intelligent electricity meters measure energy consumption in real-time and enable monitoring and optimisation. They are also crucial for prosumers – consumers who generate their own energy, for example through their solar panels. A report by the European Commission predicts that the use of smart meters can lead to annual energy savings of up to ten percent, benefiting both consumers and the environment.

“By digitising our networks, our power systems will become more reliable and secure, and our utilities will be better able to manage the balance of supply and demand,” explains IEA Executive Director Fatih Birol.

Expansion of the Network Required

However, to meet the requirements of an All Electric Society, significant network expansion is necessary: according to the “New Power Systems Report” published by the classification society DNV, global network capacity must increase 25-fold, with annual network expenditure needing to more than double to 970 billion US dollars by 2050. For Europe, this would mean, according to the industry association Eurelectric, that approximately 67 billion Euro per year should be invested in the power distribution network from 2025 to 2050, twice the current amount. This figure is relativised when considering that this sum is only 20 percent of what the EU spent on fossil fuel imports in 2023.

More Efficient Transmission with Direct Current

Network expansion is no longer limited to established alternating current technology, but increasingly includes high-voltage direct current (HVDC) transmission lines. When transmitting direct current over long distances at a voltage of 525 kilovolts, transmission losses are low compared to comparable alternating current connections. Additionally, direct current networks (DC networks) require fewer components. Renewable energy sources, which typically also operate with direct current, can be more easily integrated.

Higher Voltage, Lower Raw Material Consumption

The transformation of the energy system requires enormous amounts of raw materials, such as copper and aluminium for lines connecting renewable generators to the grid.

“An increase in system voltage can help here. Because of the associated simultaneous decrease in currents, significant raw material savings can be achieved,” explains Andreas Hensel, Group Leader of High-Performance Electronics and System Technology at the Fraunhofer Institute for Solar Energy Systems ISE.

Increasing the output voltage from 800 V to 1,500 V alternating current leads to a reduction in cable cross-section by approximately 75 percent with the same performance. Additionally, laying and connecting smaller cable cross-sections is much easier, reducing installation costs.

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Anyone who has ever been engrossed in a game knows what “immersive” means. It comes from the Latin “immersio,” meaning to dive in. In the context of computer games, the word describes the extent to which a player perceives themselves to become part of the game world. Besides the pure visuals, such as a first-person perspective, the interaction with the virtual world is decisive.

Familiarity with Digital Technology

The industry uses all the possibilities offered by modern Human Machine Interfaces, making it an exciting testing ground for new technologies. “Gaming is more than just entertainment. Through interactive gaming experiences, users are playfully familiarised with modern technology. As they dive into virtual worlds, they intuitively learn to handle digital interfaces, menus and control options,” says Dr Sebastian Klöß, head of Consumer Technology at Bitkom. Young people’s familiarity with complex Human Machine Interfaces is even utilised by the military, which uses HMIs resembling gaming controllers rather than military equipment – many systems can be used by young soldiers without intensive training.

Haptic feedback in controllers

To achieve the goal of an immersive gaming experience, manufacturers are constantly coming up with new ideas. This starts with the “simple” controller such as the PlayStation 5 from Sony: it makes the game action palpable through haptically fine-tunable vibrations. Adaptive triggers allow the adjustment of the analog shoulder buttons. In this way, certain activities in the game, such as shooting, accelerating and jumping, become more nuanced. Moreover, Sony has recently patented a new controller design that integrates an elastic area that can change its shape and temperature and respond to various physical inputs such as pressing or rubbing. This would offer new possibilities for immersion, such as the controller being able to enhance intense game moments with heat.

Measured pressure

Keyboards with force sensor technology are already a reality, although they may not be as visionary as some other technologies. They are used, for example, in special gaming laptops. Typically, the W, A, S and D keys are supplemented by a force function, making the keyboard much more intuitive and sensory for players to operate. “Imagine driving down your local highway and your accelerator is restricted to just 2 options, ‘off’ or ‘full speed’. Reality-based physics calls for acceleration dependent on how hard you press on the accelerator pedal, or how hard you turn the steering wheel. This is the difference Peratech intelligent tactile sensing makes,” explains Jim Thomas, CCO of Peratech. The company equips, for example, the Lenovo Legion 7i and 7 gaming laptops with corresponding force keys.

Capturing head movements

Lenovo’s top model can also capture the player’s head movements. The integrated software solution from Tobii Horizon uses the laptop’s built-in camera for this purpose. Players can thus control the field of view in the game with their head movements. When a player turns their head to the right, the camera follows his gaze to the right. This is particularly helpful in games where it is important to be aware of the surroundings, such as in first-person shooters or racing games.

Diving into Virtual Reality

Players can truly dive into a game through virtual reality and augmented reality technologies. Special VR glasses let the player sink into the artificially created, virtual world. These headsets can be mounts into which a smartphone is inserted, such as with Samsung Gear, or so-called “Head Mounted Displays”, which integrate the entire technology, such as Microsoft’s Hololens. In both approaches, the player is at the centre, and their virtual view follows their own movement. With its immersive and interactive nature, virtual reality has revolutionised the way games are experienced. But VR becomes truly “immersive” with input devices specially designed to make the virtual world seem more real.

Interacting with objects

Like the Oculus Touch: these handheld devices are designed to mimic hand movements in the virtual world. Equipped with sensors, buttons and triggers, the system allows the player to interact with objects and move precisely and effortlessly through virtual environments. The VR controller HTC Vive Wand also features haptic feedback – allowing the player to feel the virtual objects they interact with.

Playing with body movements

The gaming experience becomes completely realistic when the movements of the entire body can be used to guide the character through the virtual world: jumping, running, kneeling – all captured by full-body tracking systems like Omni One from Virtuix. It is an omnidirectional treadmill that allows players to walk or run in any direction through video games and other virtual environments. It is currently shipped with a Pico Neo 3 Pro headset with 6DoF technology (6 Degrees of Freedom) and additional hand controllers for hand and gesture tracking.

Empathise with the avatar

For players who still want more, in future they will be able to experience their characters’ suffering from the game. For instance, the game provider Ubisoft plans to offer a shirt with haptic feedback for its game Assassin’s Creed Mirage. With the Haptic Gaming  System from OWO, the player is supposed to experience sensations on the body that correspond with the actions in the game. “By leveraging OWO’s groundbreaking technologies and expertise, we are able to immerse players in the world, sounds and sensations of Assassin’s Creed Mirage in an innovative and enhanced way,” Fabian Salomon, lead producer at Ubisoft Bordeaux. The sensations that the shirt can convey range from wind or free fall to knife stabs, thus also exploring the limits of immersion.

Seamless interaction

But the future of VR controllers goes even beyond that. Companies like Neurable are working on Brain Computer Interfaces that allow players to control virtual environments with their thoughts. The company, a spin-off from the University of Michigan, is developing neurotechnological reference designs, APIs and capabilities that function outside of laboratory conditions and can be integrated into everyday technologies. Neurable licenses its technology for headphones, earbuds and AR devices. Dr Ramses Alcaide, CEO of Neurable, is sure that: “This is just the beginning for neurotechnology. We are at the cusp of being able to ethically create a seamless relationship between people and their technology.”

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The interaction between humans and machines is usually not one-sided, but rather a kind of communication: the operator issues a command and receives feedback on whether the command has been received. For example, with toggle switches, it is the changed position, and with push-buttons, it is often a certain resistance that must be overcome, sometimes coupled with a control light. Important for operators of many machines is also direct feedback on the force or the angle of rotation triggered by the operating part. For example, an excavator operator can feel the strength of the force with which a shovel penetrates the ground through the resistance of the operating lever of a hydraulic system. The same applies to machine tools: through mechanical operating parts, force and vibrations are transmitted directly to the hand and body of the operator.

The market for haptic touchscreens is growing rapidly

17.32 billion US dollars in 2022

47 billion US dollars in 2030

Source: Verified Market Research

Operate with feeling

With the introduction of electronic controls and operating elements, however, this haptic feedback has been lost. But thanks to microelectronics, the feeling can be replicated in modern Human Machine Interfaces. In general, sensors detect the force that the human applies to the operating part. If necessary, additional sensors also measure the force or angle at the executing part – that is, the tool, the shovel of an excavator or the wheel of a car. Micro-actuators at the operating part can then, for example, cause a noticeable counter-movement based on these measured values. The technologies used for this are summarised under the term “force feedback”.

Gaming leads the way

Such systems have been well-known in the gaming sector for a long time, for example with driving simulators: a steering wheel with force feedback technology generates vibrations and simulates gravity. High-end systems dial into the physics and the audio engine of a game to enable an ultra-realistic experience. The player feels in real time the roar of the engine of their virtual race car, the tyre traction, the nature of the terrain of the track and the feedback of the steering wheel. So it feels as if you are sitting behind the wheel of a real car.

Feedback from the car

Force feedback solutions are found not only in virtual vehicles but increasingly also in real ones: especially in the context of highly automated driving, the classic steering wheel with mechanical steering column is being replaced by mechatronic actuators – this is called steer-by-wire. Thanks to force feedback, however, the mechatronic steering wheel conveys exactly the same feeling as a classic mechanical one. Additional functions can also be realised – for example a vibration of the steering wheel when the car detects that the driver is getting tired.

Accelerator and brake pedals are also equipped with force feedback. Such active accelerator pedals with integrated actuator and freely programmable haptic signals can, for example, help the driver to drive as fuel-efficiently as possible: depending on the selected driving program, a variable pressure point in the pedal travel can be generated, which signals the optimal accelerator pedal position to the driver.

Haptic touchscreens

Even touchscreens, which are becoming increasingly popular as HMIs, can be equipped with feedback functions. If touchscreens are supplemented by sensors that measure the pressure of the finger on the surface, it is not just touch that can trigger an action, but also the press of a button. The received command can then, for example, be acknowledged by the display with a vibration. This is caused, for example, by electrostatic actuators. This haptic technology is characterised by a stroke of up to 0.8 millimetres, which allows for button-like feedback. Alternatively, piezo actuators are integrated into the display. This technology delivers a stronger and more precise haptic event. In contrast to electrostatic actuators, the deflection with piezo actuators is significantly smaller and is in the range of up to 0.3 millimetres.

Addressing the sense of touch without contact

However, operating elements are increasingly being controlled completely without contact, for example through glances, hand gestures or voice control. Until now, users have received control-related feedback in the form of displays or acoustic signals. The Institute of Construction Technology and Technical Design at the University of Stuttgart is currently working on enabling haptic feedback here as well. This involves the use of ultrasound waves: they are projected onto the palm of the hand, for example as circles, triangles or moving points, and produce a tingling sensation. Once you have learned the language of these signals, this feeling helps to move the hand in the right direction and at the right speed.

Feedback technologies are an important part of Human Machine Interfaces. They improve the user experience and open up new possibilities for the optimisation of safe and efficient workflows.

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Our daily life is now permeated by technology. With the complexity of technologies that surround us every day, there’s a growing need for Human Machine Interfaces that provide a positive user experience. The possibilities for interaction are becoming increasingly diverse: the range of HMI solutions extends from push-buttons to multi-touch screens to voice and gesture control. This breadth is something that particularly fascinates Karl Lehnhoff.

A light switch, a computer mouse, a neuroimplant for controlling a prosthesis – which of these do you consider a Human Machine Interface?

Karl Lehnhoff: That’s easy to answer – all of them. Switches are a basic HMI. But other things like a computer mouse are clearly Human Machine Interfaces. Of course, there are high-tech devices like Brain Machine Interfaces, representing the most advanced variant of an HMI.

What technologies for Human-Machine Interaction are currently in high demand?

K. L.: Let’s start with the classic: the switches. We use them everywhere. And we will continue to use them in the future. On the other hand, we are using more and more touchscreens, ranging from smartphones to those found in cars. In the future, we will integrate more haptic feedback. What’s also becoming more established is voice recognition. We’re already using it with smartphones or with Alexa and Siri in smart homes. It will be used in the future in other applications as well, for example in industrial production. Gesture control is also becoming increasingly popular.

But the HMI area also includes solutions for biometric authentication, such as facial recognition on phones or other applications, fingerprint scanners and iris scanners.

What I also find exciting are augmented and virtual reality. At this year’s Hannover Messe, for example, I observed a solution where a robot for the logistics sector is controlled via smart glasses.

Touchscreens are currently used almost everywhere – where is the development heading?

K. L.: Today, touchscreens are everywhere, and they are continually being improved and refined. We are already seeing 3D touchscreens and the possibility of integrating haptic feedback. In the future, touchscreens will also be combined with other HMI technologies such as gesture control.

How can haptic feedback be integrated into a touchscreen?

K. L.: Typically, a motor or piezoelectric actuator is used today, which provides a tangible response. There are also displays that have tactile feedback layers. They “create” buttons under the display so that you can feel when you press them. Feedback is not only relevant for touchscreens but also for other applications where buttons behind glass provide feedback. Here too, a motor is often used to provide a mechanical response. This is even possible when the operator wears gloves – although in this case, the feedback force must be greater, perhaps in a range of 1 or 2G, otherwise, you don’t feel it through the glove.

When we talk about HMIs today, we can hardly avoid AI. Besides its use in voice and gesture recognition – what role does AI play in HMIs?

K. L.: We may not always recognise it, but we are already using a lot of AI today – for example with smartphones and for voice or facial recognition. It is often used in image processing. In the future, for example with voice recognition, it will be about improving language comprehension and recognising more words. AI is also needed for Brain Computer Interfaces, virtual and augmented reality, or for predictive analysis. Machine learning will also play an increasingly important role, as it can enable the device to continue learning on its own, and perhaps even teach itself a new word.

What remains the key to an ideal user experience?

K. L.: One of the most important points is recognition accuracy. I experience this every day with my car – it understands some words, not others. So we need to have high accuracy and reliability. AI can help here. But there are a lot of other criteria for a good HMI: data protection, feedback, dealing with errors. But the most important points for me are reliability and accuracy.

With the range of technologies – how can EBV Elektronik help realise an HMI?

K. L.: We are one of the leading specialists for semiconductors. So we can help with the selection of suitable technology. We can also advise customers on software. For this, we have our segment structure with the different market and technology segments. This is also reflected in the field, with our Field Application Engineers for technologies and systems. And we can also provide support in production, supply chain management and all the other things needed to bring a product to market.

Do you also work with your sister companies from the Avnet group? How does the customer benefit from this?

K. L.: We do. For example, our sister company Avnet Abacus supplies connection technology, passive components and electromechanics. So we can cover the complete bill of materials. Avnet Embedded offers complete solutions for customer applications. They look after the development process, including production, and can work in a wide range of applications. And then we have our software specialist Witekio, which covers the entire development from the lower software levels to embedded applications and connectivity. EBV Elektronik is ultimately a full-service partner. This means the customer has only one point of contact through which they receive all the information and the entire service.

What do the current developments in the HMI sector mean from the semiconductor industry’s perspective?

K. L.: We clearly recognise the trend away from microcontrollers to microprocessors. This has a lot to do with the increasing functionalities of the touchscreen. This trend is now also transferring to other applications. The display itself is becoming more complex. This can no longer be met with microcontrollers. So in the future, it will depend on more powerful microprocessors. Of course, you also need more computing power to cater for the increasing use of artificial intelligence. Future 3D touchscreens will also require more powerful processors than in the past.

Which developments in the HMI sector do you find particularly exciting at the moment – and why?

K. L.: Voice and gesture recognition – because they enable natural interaction like with a human. They are helpful in many situations, both when driving and in industry. But the key to all this will be artificial intelligence.

Do you think we will be able to control machines with our thoughts alone in the future?

K. L.: That’s hard to say. But from a medical point of view, it’s a very interesting area. I hope this technology will be able to help people with physical limitations live better.

And do you understand the fears of many people when they think of a chip in their brain?

K. L.: On the one hand, I understand the fears, but I think it’s also a question of personal situation. Someone with a restriction and whose daily life could benefit from such a chip is likely to see the advantages. People who have no need for it are more likely to perceive it as a risk.

Finally: What fascinates you particularly about the topic of HMIs?

K. L.: For me, the fascinating thing is that the field is so broad. Starting with the on/off switch through touchscreens and voice recognition to the Brain Computer Interface. And after the HMIs we have today, something new will come along. I don’t know what it will look like, but people are investing time in research and development and trying to go new ways. I like that.

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By 2030, the EU aims to halve the number of traffic deaths and injuries. This ambitious endeavour encompasses everything from the mandate of state-of-the-art vehicle technologies to the modernisation of infrastructure. However, one factor plays a particularly significant role: the human. More than 90 percent of all accidents are caused by human error. In addition to violations such as speeding and driving under the influence of alcohol, it is important whether the driver is tired or distracted. According to the European Commission, 10 to 20 percent of accidents and near-accidents occur as a result of to fatigue.

Mandatory warning systems

To address this problem, the European Commission published a regulation in August 2021 that, since July 2022, mandates the use of Driver Drowsiness and Attention Warning (DDAW) systems. They assess the driver’s vigilance by analysing other vehicle systems such as steering and lane keeping and warn the driver if necessary.

Keeping an eye on the eyes

However, relying solely on data from other vehicle systems is not necessarily sufficient to assess a driver’s condition. Therefore, from mid-2024 in the EU, new vehicles must be equipped with an Advanced Driver Distraction Warning (ADDW) system. The first generation of ADDW solutions primarily relied on the driver’s eye movements: a camera with a CMOS image sensor monitors the driver using invisible infrared light. “The infrared light generates a reflection on the cornea of the eye, which is captured by the camera,” explains Martin Wittmann, marketing director for the sensor division at OSRAM Opto Semiconductors. “By tracking the direction of gaze, we can see whether the driver is looking at the road. The size of the pupil also indicates how awake the driver is. Finally, we can also recognise when the driver becomes tired by the movements of the eyelids.” When this is the case, the system warns the driver and redirects their attention to the road.

Supplementary health monitoring

Fatigue or lack of attention are highly complex states, so the latest generation of solutions capture additional parameters besides eye movement. The company Smart Eye has integrated the capture of vital signs into its driver monitoring software.

Using AI methods, the new function analyses several physiological signals to accurately determine the driver’s heart and respiratory rate. Smart Eye, in particular, uses remote photoplethysmography (rPPG), a contactless, camera-based method that measures fluctuations in light reflection from the skin to estimate heart rate. Another method is micro-movement analysis, which allows the software to detect subtle changes in movements associated with breathing or pulse that are not visible to the human eye. “By integrating heart and respiration rate detection into the driver monitoring system software, we provide an even deeper layer of insight into driver state and health,” says Henrik Lind, Chief Research Officer at Smart Eye. This can be lifesaving if, for example, a driver suffers a heart attack or seizure.

Combining radar, camera and AI

A more accurate capture of the driver’s condition is enabled by multi-sensor systems, such as those being developed jointly by emotion3D, Chuhang Tech and SAT. The “human analysis” software from emotion3D derives information about the driver from camera images, while Chuhang Tech’s radar solutions analyse the driver’s vital parameters. These two measurement methods are combined with SAT’s algorithms for predicting sleep onset. Wogong Zhang, CTO and co-founder of Chuhang Tech says: “We believe that our combined solution, which combines radar technology with advanced imaging algorithms, will revolutionise fatigue detection.”

Safety for automated driving

Driver monitoring systems are becoming increasingly important in view of the increasing automation of driving. As a vehicle becomes more autonomous, better safety systems are needed – for example to monitor whether a driver is ready to take over control of the car in a difficult situation. “Particularly well-functioning systems, especially in areas such as adaptive cruise control and lane keeping, tempt many road users to turn to tasks other than driving,” said Jann Fehlauer, Managing Director of DEKRA Automobil, at the presentation of the DEKRA Road Safety Report 2023. Several serious accidents have already been the result of such a misjudgment.

Driver monitoring still faces resistance

The majority of drivers are still skeptical about electronic monitoring of the driver, known as driver monitoring, for driver condition detection. At least that’s what a study by the insurance company Allianz shows. It reports that only 39 percent of those surveyed agree to camera or infrared scanning of the eyes, face, or head, where the technology anonymously only detects distraction. “We still have work to do in persuading drivers to accept driver monitoring,” says Christoph Lauterwasser, head of the Allianz Center for Technology. “It should not be about patronising, but about support. The latest vehicle and traffic technologies enable us to warn drivers when they are distracted. Just this feedback can contribute to a positive change in behaviour. We should use this to make road traffic safer for all of us.”

1.3 million people

die each year in traffic accidents around the world, according to estimates by the World Health Organization (WHO).

In accidents in Germany in 2021 where distraction played a role, 8,233 people were injured and 117 died, which is just under five percent of all fatalities (2,562).

Source: Federal Statistical Office of Germany

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In agricultural and construction machinery, the human factor is becoming even more central to human-machine communication. This means that the industry must increasingly rethink conventional operating concepts: “The construction site of the future is a more connected place, and so-called gamification will play an important role. Demographic changes and consumer preferences are pushing our industry into areas that were previously unknown or underutilised in the machine sector,” explains Vijayshekhar Nerva, head of Innovation and Acceleration at Doosan Bobcat EMEA.

Loader controlled by smartphone

A clear example of this is the remote control via smartphone developed by Bobcat. This allows the operator to remotely control their compact loader within seconds without worrying about additional devices. Using a smartphone, the machine can be sent into a dusty or potentially unsafe environment to complete its tasks while the operator stays at a safe distance. The remote control communicates with the customer’s iOS device via a Wi-Fi signal and operates within a range of up to 100 metres.

Operation via touch

The controls in the driver’s cabin are also evolving. As land and construction machinery become more complex, touchscreens are increasingly being used in the off-road sector. They allow a variety of information to be called up and displayed in a targeted manner. With special die-cast housings and robust adhesive technologies, touchscreens can also withstand the inevitable shocks and vibrations in this area. The integrated PCAP touch provides optimal conditions for comfortable control of machine functions. PCAP stands for “Projected Capacitive Touch”. This technology turns a window or glass surface into a touch-sensitive interface, allowing users to interact as they are accustomed to from a tablet or smartphone with a touchscreen.

Communication via vibration

Since the machine operator’s visual and auditory senses are already heavily demanded in daily work, the company elobau has developed a vibration module for joysticks. With certain vibration patterns, high-quality tactile feedback can be generated, making human-machine communication more efficient. The module’s vibration motor is controlled by an electronics module via the CAN bus. Manufacturers can define different parameters such as intensity, duration or number of vibrations via the CAN protocol. These parameters create individual, application-adapted and above all intuitive vibration effects. Thus, the information content to be transported can be significantly increased compared to simple punctual knocking signals.

Adaptive concept

With the multitude of functions that need to be operated in today’s work machines, the control console can quickly become cluttered. The joint project aISA (adaptive interface systems in tractors) has presented itself as a promising solution. An adaptive armrest has been developed that only provides the functions of the attachment that is in actual use. Through the Isobus, the intelligent operating armrest can adaptively adjust to any attachment as soon as it is coupled. It provides the user with an optimal and ergonomic interface in terms of position, availability, visualisation and operating mode. This includes, for example, a joystick that can assume four different positions depending on the required function (for example, it is retracted when its function is not needed). Other controls are provided via a rotary control unit. Each position adjusts depending on the attached work equipment and presents only the functions that are currently necessary.

Automated load management

When working with construction and agricultural machinery, there are typically phases of both very high and relatively low stress. “Various studies have shown that people’s well-being is highest when there is a medium level of stress,” says Professor Marcus Geimer from the Karlsruhe Institute of Technology (KIT). Overloading leads to the driver not being able to concentrate enough on the important aspects, overlooking things and becoming more prone to making errors. On the other hand, underutilisation – for example through complete automation – is also a problem. The boredom that arises leads to fatigue and loss of concentration.

As part of the “Driver’s Cab 4.0” research project, KIT is therefore developing an “adaptable Human Machine Interface” for agricultural machinery. It is capable of recognising drivers’ current stress levels via eyetracking. Research is also being conducted on a fitness bracelet that uses light signals to determine the pulse and thus measure the level of stress. If the system detects an overload, all unimportant information is faded out. In situations of underutilisation, additional tasks should be offered to the driver. “Meaningful additional tasks for phases of low stress come from accounting, personnel or material management, and the private task field,” says Patrick Lehr from the Institute of Mobile Work Machines at the Institute of Vehicle System Technology at KIT. In the future, the recommended tasks will be projected into the driver’s field of vision via an augmented reality-based interface, to avoid overloading the cabin with controls.

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Today, operating complex CNC machine tools requires several years of training and solid technical knowledge. However, the industry is increasingly suffering from a lack of suitably qualified skilled workers. Manufacturers are therefore counteracting this with intuitively operable machines. The latest machine tools are able to simplify operability through integrated feedback systems and the display of visual action prompts, so that even inexperienced operators can understand the handling of the machine in a short time.

Intuitive user interfaces

An example of this is the C.O.R.E. operating concept of the machine tool manufacturer United Grinding, which was awarded for its user and customer experience by the jury of the UX Design Awards in 2022. The core of the Human Machine Interface is a multi-touch display that largely dispenses with buttons. Self-explanatory icons simplify navigation through the machine menu and process steps. Each operator can configure their user interface individually. The user identifies themselves with an RFID chip with a stored role profile, and “their” interface is automatically called up. “It was important to us that the new operation appeals to all generations of users,” explains Christoph Plüss, CTO of United Grinding Group. “We therefore gravitated towards the operating concepts that are widely used in consumer electronics today and with which practically everyone is familiar from everyday life.”

Remote control via smartphone

This increasingly includes wireless HMI solutions that can be connected via Wi-Fi and Bluetooth. They offer maximum freedom of movement and flexibility. There is also increasing consideration of dispensing with industrial hardware for machine operation and instead using standard devices from the consumer sector. It is already common practice today for machine data to be retrievable via an app on a smartphone or wearable. However, real operation of the machine is currently only realistic for non-time-critical process control, as consumer devices do not have the necessary security architecture to ensure functional safety. Given that smartphones and tablets are particularly captivating due to their ease of use, this technology could well determine automation in the near future.

Voice-controlled user interfaces

Voice-controlled user interfaces are increasingly being integrated into industrial HMI concepts, mainly in order to complement traditional graphical user interfaces. With the increasing accuracy and performance of natural language processing (NLP) technology, machines can understand complex voice commands and respond accordingly. The company Voice Inter Connect, for example, offers voice control for industrial applications as a ready-made kit. Real-time capability, AI-based semantic analyses and algorithms for beamforming and noise cancelling ensure high operating comfort and audio quality. The system can also process acoustic feedback in the form of input prompts or text-to-speech for voice output. Thanks to local voice processing, the voice control does not need an internet connection and thus meets high standards of security and data protection.

OK by gesture

A natural extension to Human Machine Interfaces for machine tools could also be gesture control. However: “The operation of machines via interfaces is very visually oriented,” says Professor Katrin Wolf, head of the Human-Computer Interaction research group at the Berlin University of Technology. Hand movements are still rarely used for interaction.Professor Wolf says one reason for this is: “It is uncomfortable for people to learn gestures and then perform them correctly without visual feedback or support if they make errors.” In the WINK research project, Professor Wolf’s team is therefore investigating how feedback can be given via tactile stimuli. For this purpose, the scientists are constructing special bracelets for the forearm that can transmit tangible signals to the skin. To do so, the researchers have joined forces with tool manufacturer Trumpf, who is providing the use of a laser cutter to make the work process more efficient. On one side the operators push the steel plates into the industrial machine, and the cut parts emerge on the other side, where the employees check their quality. If they find faulty cuts, they have to go to the other side of the machine and record the findings via a keyboard. The idea: with a simple hand movement, such as a hook symbolising “OK”, the employees could give feedback to the machine without having to go back and forth. Trumpf uses a bracelet from Kinemic for gesture recognition. It recognises two-dimensional gestures based on movement but only returns sound and vibration via a built-in motor. However, Professor Wolf’s team wants to realise more complex vibration patterns and integrate more motors for this purpose. Although a prototype already exists, Professor Wolf is certain that: “The use of haptics for the control of digital devices will remain a research field for many years.”

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The Human Machine Interface is as old as the first machine developed by humans – thus, the history of control elements dates back to antiquity. It all began with purely mechanical levers and handwheels. With the advent of electrification, it became possible for the first time to operate controls remotely from the function or machine. This led to significant advances in operator safety and allowed users to control all functions or multiple machines from a central control station.

Various designs have been – and continue to be – used: with buttons, push-buttons, rocker switches, and toggle switches or levers, operators can trigger two mutually exclusive options – for example, on/off. Rotary knobs and switches, sliders and slide switches can be used to activate a variety of options or control a function with varying values, such as dimming a light.

Advantages of Electromechanical Controls

Although technologies such as touchscreens or smartphones are increasingly used as Human Machine Interfaces, traditional electromechanical controls still have their place. For instance, they are still essential for critical functions (emergency stop), but even. But even non-critical input operations are sometimes represented by mechanical interaction elements. Encoders, for example, enable the precise input and confirmation of values through rotary push controls, and a tactile grid provides the user with the necessary haptic feedback. The increase in industrial production, higher safety requirements and the growing use in home automation and automotive solutions is ensuring solid growth in the push-button market: market analysts from Dataintelo have predicted an annual increase of eight percent from 2022 to 2030 for industrial applications alone.

Flexibility through Bus Systems

Traditionally, individual controls were discretely connected to the corresponding actuator with one-to-one wiring. But as machines became more and more complex, the installation process became very time-consuming. For complex control systems, thick bundles of cables often needed to be connected to the plant. Today, it is possible to use control elements that communicate with actuators via a bus system, which means that all the switches and buttons are connected via just one line. This saves space and weight and significantly reduces the effort required for maintenance and diagnostics. In the industrial sector, for instance, IO-Link is often used, while in the automotive field, the CAN bus is more common. As well as significantly reducing the amount of wiring, these smart control elements also have the advantage that they can be reprogrammed. If a machine is extended, for example, a switch can be reassigned to a new function. The switching elements can also be individually configured – such as the sensitivity of capacitive buttons or the force-travel curve. Integrated microcontrollers also enable smart functions, such as the timely prognosis of maintenance needs through self-diagnosis.

In the past, especially in the field of working machines, it was often said that operators could “feel” the machine better through traditional hydraulic controls. However, today’s electronic systems also provide mechanical feedback to the machine operator with the help of “force-feedback” solutions.

HMIs for Gamers

When computers started to be integrated into machines and systems, keyboards began to triumph as a Human Machine Interface. Various technologies have become established, but mechanical keyboards are currently trending and are making particular headway among computer gamers: they use small switches under each key to send the corresponding signals. As a result, these keyboards are more expensive than membrane keyboards but offer improved performance in terms of response time and tactility, which are essential for professionals and gamers. Another advantage is their longer lifespan; they last more than 50 million keystrokes, while membrane-based keyboards can only endure about 10 million strokes. In addition, mechanical gaming keyboards allow the user to precisely adjust the operation of the keys to their needs.

Keyboards for Industry

Keyboards are also used in the industrial sector. Here, robust construction, ease of operation and reliable function are of primary importance. The input unit must be protected against vibration and shocks, or even designed to be explosion-resistant. It should be protected against water, dust, dirt, oils and chemicals, and be able to withstand temperature fluctuations. In addition to appropriately encapsulated “classic” keyboards, membrane keyboards and silicone rubber keypads are also used.

Input keyboards are often used today as a supplement to touch systems, depending on the application. Tried-and-tested input components, such as membrane keyboards, silicone rubber keypads and push-buttons remain the preferred choice – including in terms of costs – in devices that have a limited number of functions, require good visibility and are in constant use. This is because the financial expenditure for programming a graphical user interface between human and machine is a significant factor. The rule is: not everything that is technically possible is also economically viable.

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