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Why Some IO-Link Gateways Cost More – and How to Choose the Right One

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I often get asked, “Why are some IO-Link masters or Gateway modules so much more expensive than others?” It’s a valid question – nobody wants to pay more than the next best alternative that is available When I dig deeper into this topic with potential customers, I often discover that a competitor is offering an IO-Link Master (or Gateway) at nearly half the price. This leads to the assumption that all IO-Link devices must be the same, simply because IO-Link is universal. So, their question is understandable: “Why am I paying more?”

This blog intends to answer that question and offer insights on how to select the right IO-Link Gateway module for the application.

I like to explain it to prospective customers with an analogy: IO-Link is like a phone line (if you’re as old as I am, you might relate to this). You can use it to talk to someone, or you can use the same line for fax machine or a modem (now, DSL). The application determines how the line is used. Similarly, the variety of IO-Link masters on the market serve different purposes based on the specific application.

There are three main application areas in automation where IO-Link is well-suited to handling and adds value. Please note that the names I’m using for these application areas are specific to IO-Link, not universally recognized terms. The picture below illustrates these three areas.

Sensor integration

Some IO-Link gateway modules are specifically designed for integrating smart sensors and digital inputs. Due to their electrical characteristics, these modules are intended soley for smart sensor integration- While it’s possible to connect other devices, doing so would require additional cabling or complex configurations. I’m a big advocate for simplification and standardization – why complicate things? That’s why I refer to these modules as “Sensor Integration Masters (Gateways).” Typically, you’ll notice these modules have a maximum current limit of less than 4A (even if they have L-coded connectivity), and they may have separate or no output power at all.

Device integration

As you know, nearly all devices used in automation today come with IO-Link capabilities. The IO-Link consortium has even introduced a new category of IO-Link devices called “Class B” or “Type B” IO-Link devices. These “Device Integration” gateway modules, typically support both Class A and Class B type devices. Class B devices, such as valve banks or end-of-arm grippers/tooling, have slightly different pin-out to support Isolated Output Power.

When you choose this type of gateway module, you will notice that the master (gateway) ports are labeled separately as Type A and Type B. There’s a good reason for this. To connect a Class A smart sensor, you’ll need to use a 3-pole cable, while a Class B device (e.g., valve bank) requires a 5-pole cable. If you accidentally connect a smart sensor to a Class B port with 5-pole cable, you could damage your sensor. Most operators avoid Class B gateway module and devices for two main reasons:

  1. When using double-ended cord sets to speed up the build and maintenance, it can be hard to distinguish between 3-pole and 5-pole cables without careful attention.

  2. From maintenance perspective, keeping multiple different types of cord sets leads to extra cost and the risk of connecting devices to the wrong ports.

Controls architecture

Some gateway modules are designed to make the entire controls architecture smarter, rather than just adding a few smart sensors or smart devices in the existing architecture. These gateway modules typically support high output power, up to 16A, and can integrate safety circuitry to switch off power when needed.

 

In a nutshell, these gateway modules, when combined with IO-Link hubs, create a resilient and scalable architecture. They allow seamless integration of digital and analog inputs and outputs, valve banks, RFID systems, vision systems, motor control, smart sensors, smart visualization devices, and more. By minimizing the number of network nodes and using 4-pole double-ended cord-sets, these modules offer tremendous cost savings and are easy to maintain.

Given this information, sensor integration masters may seem more cost effective, but they are limited to integrating only smart devices. The controls architecture masters, on the other hand, may appear more expensive upfront, but they significantly bring down the total cost per point.

Customers can choose the appropriate master (gateway) modules based on their specific application needs. In some cases, a combination of different gateway modules may be the best solution.

Click here for details about different controls architecture scenarios.

Keywords

  • IO-Link

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Shishir Rege

Shishir Rege


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