IO-Link is well-suited for use in measurement applications that have traditionally used analog (0…10V or 4…20mA) signals. This is thanks in large part to the implementation of IO-Link v1.1, which provides faster data transmission and increased bandwidth compared to v1.0. Here are three areas where IO-Link v1.1 excels in comparison to analog.
Fewer data errors, at lower cost
By nature, analog signals are susceptible to interference caused by other electronics in and around the equipment, including motors, pumps, relays, and drives. Because of this, it’s almost always necessary to use high-quality, shielded cables to transmit the signals back to the controller. Shielded cables are expensive and can be difficult to work with. And even with them in place, signal interference is a common issue that is difficult to troubleshoot and resolve.
With IO-Link, measurements are converted into digital values at the sensor, before transmission. Compared to analog signals, these digital signals are far less susceptible to interference, even when using unshielded 4-wire cables which cost about half as much as equivalent shielded cables. The sensor and network master block (Ethernet/IP, for example) can be up to 20 meters apart. Using industry-standard connectors, the possibility for wiring errors is virtually eliminated.
Less sensor programming required
An analog position sensor expresses a change in position by changing its analog voltage or current output. However, a change of voltage or current does not directly represent a unit of measurement. Additional programming is required to apply a scaling factor to convert the change in voltage or current to a meaningful engineering unit like millimeters or feet.
It is often necessary to configure analog sensors when they are being installed, changing the default characteristics to suit the application. This is typically performed at the sensor itself and can be fairly cumbersome. When a sensor needs to be replaced, the custom configuration needs to be repeated for the replacement unit, which can prolong expensive machine downtime.
IO-Link sensors can also be custom configured. Like analog sensors, this can be done at the sensor, but configuration and parameterization can also be performed remotely, through the network. After configuration, these custom parameters are stored in the network master block and/or offline. When an IO-Link sensor is replaced, the custom parameter data can be automatically downloaded to the replacement sensor, maximizing machine uptime.
Diagnostic data included
A major limitation of traditional analog signals is that they provide process data (position, distance, pressure, etc.) without much detail about the device, the revision, the manufacturer, or fault codes. In fact, a reading of 0 volts in a 0-10VDC interface could mean zero position, or it could mean that the sensor has ceased to function. If a sensor has in fact failed, finding the source of the problem can be difficult.
With IO-Link, diagnostic information is available that can help resolve issues quickly. As an example, the following diagnostics are available in an IO-Link magnetostrictive linear position sensor: process variable range overrun, measurement range overrun, process variable range underrun, magnet number change, temperature (min and max), and more.
This sensor level diagnostic information is automatically transmitted and available to the network, allowing immediate identification of sensor faults without the need for time-consuming troubleshooting to identify the source of the problem.
To learn about the variety of IO-Link measurement sensors available, read the Automation Insights post about ways measurement sensors solve common application challenges. For more information about IO-Link and measurement sensors, visit www.balluff.com.
style form factors are used to measure very short distances, typically in the 1…5 mm range. The operating principle is similar to a standard on/off inductive proximity sensor. However, instead of discrete on/off operation, the distance from the face of the sensor to a steel target is expressed as a continuously variable value. Their extremely small size makes them ideal for applications in confined spaces.
Laser distance sensors use either a time-of-flight measuring principle (for long range) or triangulation measuring principle (for shorter range) to precisely measure sensor to target distance from up to 6 meters away. Laser distance sensors are especially useful in applications where the sensor must be located away from the target to be measured.
flexible magnet tape and a compact sensing head to provide extremely accurate position, absolute position feedback over stroke lengths up to 8 meters. Flexible installation, compact overall size, and extremely fast response time make magnetic linear encoders an excellent choice for demanding, fast moving applications.
Incremental encoders are pretty simple and straightforward. They provide digital pulses, typically in A/B quadrature format, that represent relative position movement. The number of pulses the encoder sends out correspond to the amount of position movement. Count the pulses, do some simple math, you know how much movement has occurred from point A to point B. But, here’s the thing, you don’t actually know where you are exactly. You only know how far you’ve moved from where you started. You’ve counted an increment of movement. If you truly want to know where you are, you have to travel to a defined home or reference position and count continuously from that position.
Absolute encoders, on the other hand, provide a unique output value everywhere along the linear travel, usually in the form of a serial data “word”. Absolute encoders tell you exactly (absolutely) where they are at all times. There’s no need to go establish a home or reference position.
