Optimising Welding Machine HMIs A Human-Centred Design Approach to Usability and Facilitation of Automated Welding Machines

Abstract

As welding systems become more automated and intelligent, the Human-Machine Interfaces (HMI) become crucial for utilising the advantages such systems aim to achieve. This thesis explores what modern user interface design principles should be considered when designing the Human-machine interface (HMI) of industrial welding machines. A pre-study involving interviews, observations, and operator feedback provided insights into Submerged Arc Welding (SAW), Industry 4.0, and intelligent welding systems (IWS). The project then underwent four iterations of design and evaluation, including problem definition, ideation, prototyping, user testing, and analysis. Using a human-centred design approach, key findings highlighted the importance of customisation, intuitive navigation, clear communication, appropriate permission levels, and reducing cognitive load. These insights informed specific design guidelines to improve HMI usability. Our results confirm that a human-centred approach effectively addressed the research question and project aim. However, the guidelines need further validation through extensive user testing and real-world application. In conclusion, this thesis demonstrates that user feedback leads to more user-friendly and efficient HMI designs, supporting the transition to automated and intelligent welding systems. Future work should focus on validating these guidelines to solidify their industry application.