Products
06.11.2023
IO-Link: the intelligent networking solution
When Ready Systems from Burlington, Ontario, Canada was looking for a way to simplify their Ethernet network, they turned to their longtime partner Balluff. The solution: the open communication standard IO-Link.
“It looks like a normal conveyor belt that transports the seats along the assembly line,” says Ron Heyden, co-owner of Ready Systems, describing their car seat conveyor system. “It all looks pretty simple, however, it requires complex programming and data collection." Since Ready Systems was founded in 2007, the company has made a name for itself as a manufacturer of pallet-based assembly lines — and not just in the automotive industry.
Tracking parts critical to safety
Car seats have a great impact on vehicle safety. Therefore, traceability from production to installation over the entire lifespan of the vehicle is enormously important. That is why Ready Systems records all relevant data during the production process to ensure traceability for each individual seat. What makes Ready Systems so competitive is its ability to handle a wide range of seat configurations without any issues.
IO-Link as the backbone of the control architecture
In order to easily capture, track, and process these large amounts of data, Ready Systems chose IO-Link as the backbone of their control architecture, RFID to ensure traceability of work processes, and various smart sensors for data collection.
Before the introduction of IO-Link, the use of Ethernet required a large number of Ethernet connections, with each module requiring its own cable. The result: a large number of Ethernet cards in the control system, more Ethernet switches, and an enormous amount of wiring along with an elevated susceptibility to errors.
Simplifying the entire network architecture
The communication standard IO-Link enables seamless communication between sensors, actuators, and the control level. IO-Link can connect up to eight devices with one master, allowing up to 256 discreet connections to a single Ethernet IP address. This reduces the number of devices in the network, simplifies the entire network architecture, and reduces the amount of wiring required.
“The switch to IO-Link allowed us to reduce the number of devices in the network by 75% and the wiring required by 25%,” says Heyden. “We’re able to operate an entire line with a single Ethernet card and just one ring, making troubleshooting much easier. This way we can take on more projects because we finish faster, but it also makes us more efficient and cost-effective.”
Switching IO-Link has reduced the wiring required by 25%.
The system solution consisting of intelligent sensors, RFID, and IO-Link makes it possible to track pallet IDs.
Enormous flexibility thanks to IO-Link
The biggest incentive for switching to IO-Link, however, was the flexibility of the devices compatible with IO-Link, which range from intelligent sensors to RFID readers for tracking pallet IDs or intelligent lighting with various light and acoustic signals in order to inform employees about the machine status.
“This makes maintenance, troubleshooting, or changing devices easier,” says Greg Soden with Balluff Canada, who oversaw the switch to IO-Link from the very beginning. "The standardized data formats also make it possible to merge different data from different manufacturers and suppliers within one line."
Open standard
For Balluff, it is clear that open standards not only offer advantages to the customer. They are the future for intelligent and flexible production systems in the Industrial Internet of Things because they offer a high degree of compatibility across different manufacturers. “If a company relies on open standards, it creates a competitive advantage for itself. This is because they increase the acceptance and rapid dissemination of the company's own products,” says Soden. This is why Balluff is well connected, participates in further developing open standards, and is also a member of various committees such as the IO-Link Community.
“Balluff is our preferred partner for IO-Link.”
Ron Heyden | Co-owner of Ready Systems
Where the customers are
“Balluff is our preferred partner for IO-Link,” says Heyden, praising the collaboration. Why? “A strong local customer service and technical support on site, both in Canada, the U.S., and Mexico.”
