Develop HMI systems Mechanical buttons remain indispensable in cars despite touchscreens

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Despite the increasing use of touchscreens in modern vehicles, the mechanical button remains an indispensable element—especially in safety-critical applications. Developers face the challenge of creating robust and reliable HMI systems that integrate both tactile feedback and modern technologies such as wireless interfaces.

Human-Machine Interfaces (HMI) are the crucial link between humans and machines. The Swiss company EAO specializes in this technology. With a wide portfolio of components and systems for human-machine interaction, EAO has been successfully operating worldwide in industries such as the automotive industry, rail vehicles, and industrial automation since its founding in 1947.

One of EAO's most significant branches is located in Auerbach in the Vogtland region, an area with a long industrial tradition and an optimal location near important production and development centers in Germany. At the Auerbach site, EAO's experts develop mechatronic systems specifically for the automotive industry, as well as special and custom vehicles. By 2027, the company plans to expand this location into a state-of-the-art development, production, and logistics center and create up to 150 new jobs.

Requirements and challenges for operating controls in vehicle construction

In conversations with the experts at EAO Automotive in Auerbach (Germany), the current challenges in developing vehicle operating elements become clear. Particular focus is placed on haptic feedback, uniform illumination, and robust surfaces that meet the high-quality standards and specific requirements of vehicle construction. EAO relies on electromechanical buttons, which still fulfill a central safety-related function in the vehicle. These are complemented by modern interfaces such as CAN, LIN, and wireless configurations.

The development of such operating controls requires interdisciplinary teams, close cooperation with OEMs, and the integration of innovative technologies such as displays and sensory surfaces. Safety and functionality are guaranteed by standards like ISO 16750 and ISO 26262, which ensure that the operating units withstand the extreme demands in automotive construction.

The significance of optical and haptic properties

For developers, optical and haptic properties play a central role in the design of vehicle operating elements. In addition to mechanical reliability, factors such as surface quality, symbolism, and lighting must be considered, as they significantly influence the user experience. Uniform illumination is crucial to create a homogeneous appearance, even under challenging lighting conditions such as direct sunlight.

The selection of the right materials and manufacturing techniques is another critical factor, especially regarding resistance to extreme climatic conditions. To avoid issues like material fatigue and malfunctions, EAO subjects its products to comprehensive validation processes, including dust, climate, and salt spray tests as well as vibration and shock tests. These tests guarantee the longevity and safety of the operating elements, which are essential for safety and functionality in the vehicle.

A look at the norms and standards as a guarantee of safety

Another central topic for electronics developers in the automotive sector is the numerous norms and standards that must be adhered to. Among the most important are ISO 16750 (test and environmental conditions), ISO 20653 (degrees of protection), as well as ISO 26262 and EN ISO 13849 (functional safety). These standards specify the conditions that products must meet to be used safely in vehicles.

It is not enough to merely meet the mechanical requirements. The electrical and electronic properties must also meet the highest standards. In safety-critical applications, where the protection of life is concerned, developers use methods such as FMEA (Failure Modes and Effects Analysis) to identify and address potential sources of error early on. Such product development is hardly possible without interdisciplinary collaboration, often between electronics, mechanical, and software engineers.

User-friendliness at the focus of development

User-friendliness is increasingly at the forefront of HMI system development. The experts at EAO, in particular, place great importance on precise haptic feedback with mechanical buttons, as this is crucial in safety-critical applications. The haptic feedback is designed to function reliably even under challenging conditions, such as operation with gloves.

Another challenge for developers is finding the balance between mechanical controls and modern touchscreens. Although touchscreens are increasingly being used in many vehicles, the mechanical button remains indispensable for safety-related functions. Hybrid solutions, combining mechanical and electronic controls, are often the best way to meet the demands for safety and comfort.

Hybrid solutions, combining both mechanical and electronic controls, are ideal for meeting the demands for safety and comfort. Lighting in HMI components is also not to be neglected. Developers must ensure that optical feedback is provided through various lighting features when designing user interfaces.

Interdisciplinary collaboration and employee integration

At EAO, interdisciplinary collaboration is a central aspect of product development. Their products combine mechanical, electronic, and software components, requiring close cooperation between various specialist fields. This exchange between mechanical, software development, and quality assurance teams is important not only during the development phase but throughout the entire process up to series production.

Production employees are involved early in the development process to ensure that the products can later be manufactured and assembled efficiently. Additionally, feedback from the quality department plays a crucial role. Series products are regularly reviewed, and the feedback is incorporated into future development projects. For developers, this means focusing on quality and reliability from the start and continuously learning from previous projects.

Future prospects: new technologies and connectivity

Although EAO focuses on mechanical buttons, the company is increasingly integrating new technologies. These include wireless interfaces, CAN and LIN bus systems, as well as displays and sensory control surfaces. Another future topic is the growing connectivity of vehicles. Developers at EAO are increasingly working on creating interfaces for wireless communication that facilitate the configuration and control of operating elements. The integration of displays in control units is becoming increasingly important to offer the driver an intuitive and seamless user experience. (heh)