Reliability and comfort

In the previous part of the article we presented the operation of the novel IO-Link standard, as well as the tools dedicated to this technology and the tasks they fulfill.

The build quality of such devices must be very high.They are often operated in very harsh industrial conditions, which commercial equipment would not cope with. Many Balluff devices in the IO-Link area have a metal housing, while the interior is potted with resin. This makes the equipment resistant to the ingress of liquids and dust. It is also protected against damage from impacts and shocks. The devices provide a high degree of protection (IP65, IP67). All this means that IO-Link components can be conveniently mounted anywhere on the machine.

Balluff sensors communicating over IO-Link do not differ in size from standard versions of these devices. The use of the classic M12 & M8 connector is extremely convenient: when connecting different types of sensors, there is no need to study technical documentation. No matter what kind of device it is, connection always takes only a few minutes and the system is ready for operation.

The 24V power supply for all devices is a key element in the operation of the automation system. So it is worth taking advantage of the possibility to connect this element to IO-Link as well. By equipping power supplies with an IO-Link interface, it is possible to monitor their operating parameters, and thus take a predictive approach to maintenance. With the help of a master control system, it is possible to control the current status of power supply equipment, e.g. current and temperature load, as well as their service life. This minimises losses associated with unplanned production downtime.

Inductive couplers

Inductive couplers are an alternative solution to the classic wired connection - energy and data are transmitted through a 5-millimeter air gap. They are best used in areas where wire connections are subjected to significant mechanical loads - for example, where a large number of tool coupling and uncoupling operations are performed. Examples include robots with variable grippers, as well as fixed rotary or machine changeover processes in which there are frequent tool changes.
The IO-Link inductive coupler is a component that reduces production costs and provides flexibility. It significantly speeds up processes and eliminates the need for frequent replacement of mechanical components that wear out quickly with intensive use.

System configuration

A properly configured system will ensure optimum performance and maximum utilisation of the possibilities offered by IO-Link, so it is worth taking a close look at the process.

IO-Link configuration

The IO-Link Master has a built-in Web Server, through which we can change the basic settings of the device, such as the mode of IO-Link ports (IO-Link - communication, DI - digital input, DO - digital output, deactivation - unused port). We use this option when we don't have a PLC connected yet, but we want to perform configuration of IO-Link devices. However, we must remember that after connecting the Master to the controller via the industrial network, the configuration is done from the PLC software using files such as GSDML in the case of Profinet . Configuration files such as GSMDL give users a very wide range of possibilities to set the functions of the IO-Link master itself and to configure the entire IO-Link topology with all its elements.

IO-Link Device configuration can be done in one of several ways. You can use the configuration softwareBalluff Engineering Tool (BET)(BET) and an IO-Link - USB signal converter. In this way, any device can be configured - no matter where it will operate in the future. The application requires the use of IODD configuration files, which can be downloaded from each manufacturer's website.

Another option is to use the aforementioned Web Server - you connect to the Master IO-Link device by entering its IP address in a Web browser. A wired Master to PC connection is required, of course. Here, too, IODD files will be very helpful, allowing user-friendly graphical parameterisation. Configuration can also be carried out classically using the addresses of the configuration parameter registers, which are described in detail in the technical documentation of the devices. This is a more time-consuming way, but it makes the user aware of how asynchronous communication in the IO-Link protocol works.

The technical documentation describing the addresses of the individual parameters will certainly be necessary if you choose the third way of configuring the devices, namely setting up the IO-Link devices from the PLC software. To do this, use special function blocks prepared by the respective PLC manufacturer.

Why exactly IO-Link?

IO-Link provides fast, simple installation and configuration of devices. All components are connected with one type of cable, which significantly reduces the time of system installation, hardware costs and repair of possible failures. The standard significantly speeds up not only finding faults that have occurred, but also detecting where they could potentially occur, so eliminating failures does not involve costly production downtime. When replacing an IO-Link Device, the new device can be automatically parameterised. With IO-Link, consistent control of all diagnostic and process data is possible, as well as communication between system components.

The number of IO-Link devices continues to grow in the automation market. No wonder - this solution has many advantages and it is very likely that it will soon dominate systems in automation, displacing older technologies.