Comparing “IO-Link” and “Safety” to “IO-Link Safety”
There are many I/O blocks that have “IO-Link” and “Safety” in their descriptions, which can cause some confusion about which safety features they include. Here’s an overview of different safety-named blocks and how they compare to IO-Link Safety.
Safety Network Blocks
These blocks have I/O ports that use Pin 4 and Pin 2 as OSSD signals (safety ports). OSSD—output switching signal devices—send 24-volt signals over two wires to confirm that a device is operating in a safe condition. If 0 volts are detected in either signal, besides their safety-checking 0-volt pulses, it’s read as a safety event that signals the machine to go into a safe state. Safety network blocks are only for standard (non-network) safety devices. These blocks communicate directly back to a Safety Controller over safety protocols like CIP Safety, PROFIsafe, etc. These blocks typically can monitor between 8-16 standard safety devices. There is no intelligence built into the safety devices.
Safety Network Blocks with IO-Link
Blocks in this category usually have a mixture of I/O ports on them. The ports can range from standard I/O to standard IO-Link communication, and in addition, include ports that use Pin 4 and Pin 2 as OSSD signals (safety ports). These blocks communicate over the safety protocols with only a few ports to connect standard (non-network) safety devices. There is some versatility with these blocks since you can wire standard sensors, IO-Link devices, and safety devices to it. The drawback is, you will always run short of the port style you need and, in the end, use more blocks to cover either the safety or IO-Link needs of the application. There is no intelligence built into the safety devices.
Safety over IO-Link Blocks
In this system/architecture, there are standard IO-Link Masters communicating to the Safety PLCs/Controllers over standard protocols like EtherNet/IP, PROFINET, etc. Connected to the IO-Link Ports of these Masters are Safety over IO-Link devices, currently limited to only Safety over IO-Link hubs. The Safety PLCs/Controllers communicate via safety protocols like PROFIsafe to the standard IO-Link Master, and then using the IO-Link communication channel, they bridge the gap to the Safety over the IO-Link hub via the “black channel.” These Safety over IO-Link hub’s ports use Pin 4 and Pin 2 as OSSD signals (safety ports), so standard (non-network) safety devices can be connected. This system provided a “gap filler” while IO-Link Safety was being developed. In this system/architecture, the standard IO-Link Masters allowed standard IO-Link devices and Safety over IO-Link hubs to be connected to any ports. This brought even more versatility to an application and the beginnings of the benefits of IO-Link. Still, there is no intelligence built into the safety devices.
IO-Link Safety adds a safety communication layer to IO-Link. The difference between this and Safety over IO-Link is that this safety layer applies to both the IO-Link Master and IO-Link Safety devices. Within a CIP Safety or PROFIsafe network, the safety communication protocol has top priority over standard EtherNet/IP or PRIFONET data if both are existing on the same physical network. The same is true for IO-Link Safety: both standard and safety IO-Link protocols can exist on the same physical cable between the IO-Link Master ports and IO-Link Safety devices, with IO-Link Safety carrying the top priority. For a deep dive into the IO-Link Safety protocol, I suggest visiting the IO-Link Consortium’s website at io-link.com. In this system/architecture, you have IO-Link Safety Masters, which communicate to the Safety PLCs/Controllers over safety protocols like CIP Safety, PROFIsafe, etc. The ports on the Masters can utilize Pin 4 and Pin 2 as OSSD signals (safety ports), so standard (non-network) safety devices can be connected. Pin 4 can also be used to carry standard IO-Link and IO-Link Safety communication to standard IO-Link devices and IO-Link Safety devices, respectively. This allows for the most versatile safety solution in the market–IO-Link Safety Masters that can accept standard (non-network) safety devices, standard IO-Link devices, and IO-Link Safety devices. Intelligence in the IO-Link Safety devices is now available.
Benefits of IO-Link Safety
- IO-Link Safety devices are fieldbus neutral: you just need to specify the IO-Link Safety Master to match the Safety PLCs/Controllers protocol.
- IO-Link Safety Master port versatility: standard (non-network) safety devices, standard IO-Link devices, and IO-Link Safety devices can be connected.
- Parameter storage: standard IO-Link and IO-Link Safety device’s parameters can be stored for ease of device replacement.
- Smart IO-Link Safety device data: more data available, like internal temperature, humidity, number of cycles, power consumption, diagnostics, etc.
- Simplified wiring: IO-Link Safety devices are still connected to the IO-Link Master port with a standard 3 to 4 conductor cable.
- IIoT fit: IO-Link Safety gives more visibility to upper-level systems like SCADA, allowing safety device-level monitoring.
I am looking forward to seeing how quickly IO-Link Safety will be accepted, with how IO-Link numbers have skyrocketed over the last few years. The future looks great for IO-Link with IO-Link Safety, IO-Link Wireless and in the future, Single-Pair Ethernet (SPE). With all these new capabilities, what application can’t IO-Link support?