With almost twelve million installed nodes as of 2019, IO-Link is being rapidly adopted in a wide range of industries and applications. It is no wonder since it provides more flexibility in how we build and maintain our machines and delivers more data.
As an IEC standard (IEC 61131-9), IO-Link provides consistency in how our devices are connected and integrated. With an already large and ever growing base of manufacturers providing IO-Link devices, we have an incredible amount of choice when it comes to what vendors we use and what devices we incorporate into our systems, all while having the confidence that all of these devices will work and communicate together. Fieldbus independent and based on a point-to-point connection using standard 3 and 4 wire sensor cables, IO-Link allows designers to replace PLC input cards in the control cabinet with machine-mounted IO-Link masters and input hubs. This technology means we are drastically less limited in how we design our machines.
IO-Link is well known for simplifying and reducing build time of machines. Standardization of connections means that readily available double ended quick disconnect sensor cables can replace individually terminated wires, and analogue devices and devices using RS232 connections can be replaced with IO-Link devices which connect directly to a machine mounted IO-Link master or IO hub. Simplified wiring along with delivered diagnostics leads to greatly simplified network architecture and reduced build/commissioning time, as well as increased trouble shooting ability. This all leads to reduced hardware and labor cost.
When it comes to the software side of things, you might think that all of this additional functionality and flexibility increases the burden on programmers, however through the use of configuration files provided by the device manufacturers for both the IO-Link devices and the PLC, this additional functionality and data is at our fingertips with minimal time and effort. With the large adoption of IO-Link and growing manufacturer base comes great amounts of reference material, videos, example programs, and support, all of which can help to get our systems up and running quickly.
When it comes to operation IO-Link opens a world of possibilities. Bidirectional communication of not only process data but diagnostics and parameter data delivers real time visibility into the entire system during operation all the way down to the device level. Things like automated or guided changeover become possible, for example if a manufacturer produces two different parts on the same line, after the production of part A, devices can be reparameterized for production of part B with the push of a button.
Maintenance sees massive benefits from IO-Link thanks to reduced unplanned downtime through device diagnostics which allow for predictive maintenance practices. If a device does get damaged or fails at an inconvenient time, the issue can be found much quicker and be replaced. Once the IO-Link master recognizes that the device was replaced with the same hardware ID, it can automatically reparameterize the device.
IO-Link is already making our lives easier and providing manufacturers with more possibilities in their automated systems, and as we push into Industry 4.0 it continues to prove its value.
For more information on IO-Link and Industry 4.0 visit www.Balluff.com