When looking at flexible manufacturing, what first comes to mind are the challenges of handling product changeovers. It is more and more common for manufacturers to produce multiple products on the same production line, as well as to perform multiple operations in the same space.
Accomplishing this and making these machines more flexible requires changing machine parts to allow for different stages in the production cycle. These interchangeable parts are all throughout a plant: die changes, tooling changes, fixture changes, end-of-arm tooling, and more.
When swapping out these interchangeable parts it is crucial you can identify what tooling is in place and ensure that it is correct.
ID without RFID
When it comes to identifying assets in manufacturing today, typically the first option companies consider is Radio-Frequency Identification (RFID). Understandably so, as this is a great solution, especially when tooling does not need an electrical connection. It also allows additional information beyond just identification to be read and written on the tag on the asset.
It is more and more common in changeover applications for tooling, fixtures, dies, or end-of-arm tooling to require some sort of electrical connection for power, communication, I/O, etc. If this is the case, using RFID may be redundant, depending on the overall application. Let’s consider identifying these changeable parts without incurring additional costs such as RFID or barcode readers.
Hub ID with IO-Link
In changeover applications that use IO-Link, the most common devices used on the physical tooling are IO-Link hubs. IO-Link system architectures are very customizable, allowing great flexibility to different varieties of tooling when changeover is needed. Using a single IO-Link port on an IO-Link master block, a standard prox cable, and hub(s), there is the capability of up to: 
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- 30 Digital Inputs/Outputs or
- 14 Digital Inputs/Outputs and Valve Manifold Control or
- 8 Digital Inputs/Outputs and 4 Analog Voltage/Current Signals or
- 8 Analog Input Signals (Voltage/Current, Pt Sensor, and Thermocouple)
When using a setup like this, an IO-Link 1.1 hub (or any IO-Link 1.1 device) can store unique identification data. This is done via the Serial Number Parameter and/or Application Specific Tag Parameter. They act as a 16- or 32-byte memory location for customizable alphanumeric information. This allows for tooling to have any name stored within that memory location. For example, Fixture 44, Die 12, Tool 78, EOAT 123, etc. Once there is a connection, the controller can request the identification data from the tool to ensure it is using the correct tool for the upcoming process.
By using IO-Link, there are a plethora of options for changeover tooling design, regardless of various I/O requirements. Also, you can identify your tooling without adding RFID or any other redundant hardware. Even so, in the growing world of Industry 4.0 and the Industrial Internet of Things, is this enough information to be getting from your tooling?
In addition to the diagnostics and parameter setting benefits of IO-Link, there are now hub options with condition monitoring capabilities. These allow for even more information from your tooling and fixtures like:
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- Vibration detection
- Internal temperature monitoring
- Voltage and current monitoring
- Operating hours counter
Flexible manufacturing is no doubt a challenge and there are many more things to consider for die, tooling and fixture changes, and end-of-arm tooling outside of just ID. Thankfully, there are many solutions within the IO-Link toolbox.
For your next changeover, I recommend checking out Non-Contact Inductive Couplers Provide Wiring Advantages, Added Flexibility and Cost Savings Over Industrial Multi-Pin Connectors for a great solution for non-contact connectivity that can work directly with Hub ID.
