The foundation for intelligent sensors and actuators

16 June, 2017

IO-Link: watch this space

One of these relatively new open communications protocols, IO-Link, could be the next significant industrial network protocol being a perfect local extension of a superior Industrial Ethernet network. Started in 2008 by Siemens, it is the first IO technology for communication with sensors and actuators to be adopted as an international standard (IEC 61131-9), meaning that devices can be integrated in the same way in all commonly used fieldbus systems and automation systems, right up to enterprise resource planning (ERP) level.

The high-performance point-to-point interface is based on the 3-wire connection that has all the simplicity of a plug-and-play installation. IO-Link uses standard, non-shielded cables to connect slave devices to the IO-Link master. This reduces the cost of cabling by a factor of five compared to protocol-specific cables.

Each device’s configuration can be stored and downloaded into a new device if a replacement is needed, with no programming required.

The key to unlocking the power of these intelligent devices is in making this diagnostic information easy to access. IO-Link allows for cyclic data exchange capabilities so a programmer can easily send the valuable information directly to where it needs to go, either to an HMI screen, a signal light, or a maintenance request. If sensor or actuator parameters need to be changed or calibrated, that can be done remotely; even while the production line is still running, and that means shutdowns and stoppages can be avoided. If sensor or actuator parameters need to be changed or calibrated, that can be done remotely; even while the production line is still running, and that means shutdowns and stoppages can be avoided.

Parker Hannifin has joined more than 130 companies in the IO-Link community which represents over 3.5 million nodes achieved in the field, number in a fast evolution/acceleration, factors such as the ease of installation, greater control and improved diagnostics capabilities of IO-Link has won the technology a substantial user base. It seems this type of IO technology is a definitive stride towards the ‘smart factory’ of intelligent devices that manufacturers have been eagerly awaiting.

Doing more with less

If you visit any automotive or packaging plant, the ‘elephant in the room’ is usually the big controller cabinet housing the PLCs and contactors. These cabinets take up a lot of valuable floor space, but now it seems that the cabinet is destined to shrink dramatically. Power supplies, PLCs and Ethernet switches are becoming more rugged, going from IP 20 to IP 65 ratings in many instances. With equipment such as safety relays increasingly moving out of the cabinet, we will start to see the PLC moving out to the tool itself.

Ultimately, factories will regain that premium space that was once occupied by the cabinet and IO-Link masters installed so that the cables are also decentralised. Both will see a dramatic decrease in cost.

This stripped-down ‘do more with less’ business model will encourage those customers who still typically hard wire their valve manifolds to make that leap towards industrial networks, because we now have the power to put real-time intelligent diagnostics into valve manifolds. The customer can easily see if a coil has been shorted or if the voltage is sagging. There’s a lot of information that users can get now that they couldn’t before, simply because there is more intelligence in that pneumatic manifold, enabling flexible manufacturing and better safety.

www.parker.com