More Speed with IO-Link: Five Practical Tips for Engineers

With IO-Link, machine designers and plant operators hold the key to the digital factory in their hands. But not everyone knows and exploits the full potential of smart technology. Because IO-Link offers more than easy parameterization and quick sensor replacement. With five examples taken from the daily routine of machine builders and plant operators, the present report will show how users can benefit from IO-Link to speed up engineering and optimize maintenance intervals. Center element is a fast IO-Link all-in-one package allowing for high-speed data transmission from sensor to PLC.

Example 1: IO-Link Available in Packaging

Previously, IO-Link used to be inappropriate for applications with very short response times. An example of very dynamic applications are packaging machines that require very high transmission speed. Packaging machines are designed for high speed since the motto "time is money" here is even more important than in other fields of automation. The faster the belt is running "trouble-free" in operation, the higher the cost-efficiency for the plant operator. The emphasis is on "trouble-free," since packaging has high demands on system uptime. For example, if the belt stops during packaging of pre-processed fresh fish, often the entire batch has to be disposed of and the packaging installation has to be cleaned. Such expensive scenarios must be avoided. Therefore, knowing about machine shutdowns weeks in advance is something plant operators dream of. With this knowledge, maintenance could be perfectly timed — not unnecessarily often, but well in advance before a shutdown — for example, during the maintenance shift on Sunday.

Previously, the overall IO-Link system was not fast enough to meet this requirement for on-demand maintenance. Though IO-Link could supply the required secondary data, transmission of the system's primary data to the PLC would not be fast enough. The bottleneck was the IO-Link master. It used to be too slow for fast transmission of primary data. Root causes were PLC cycle times of 4 ms (or significantly less) in packaging installations. Conventional inputs (analog and switching) are fast enough, but IO-Link used to be significantly slower, often >10ms.

Baumer eliminates this bottleneck with its new high-speed IO-Link all-in-one package. The company supplies sensors featuring <1ms cycle time and correspondingly supportive IO-Link masters. For this reason, now IO-Link can be used in one of the fastest machine types on the market — packaging machines. In terms of speed, the IO-Link network is no longer behind conventional wiring. And on top of all: thanks to secondary data, sensors report on contamination and alignment issues and will detect any excess temperature at an early stage.

Example 2: Condition Monitoring for On-Demand Maintenance

The example of the exposure reserve shows how condition monitoring works. Optical sensors from Baumer report via secondary data whether the reflected light is still sufficient for correct measuring or switching operations. This way, the sensor can "see" when the glass is contaminated or it is no longer correctly aligned. Other useful sensor data for on-demand maintenance includes temperature, vibration, overload (force and pressure), power consumption or service life.

Example 3: Speed up Engineering With the Baumer Sensor Suite

IO-Link sensors are the key to efficient sensor engineering, and with the Baumer Sensor Suite (BSS), Baumer also provides the related freeware. This intuitive tool simplifies the evaluation, parameterization and use of IO-Link sensors and actuators. On screen, users can see what the sensor is seeing. Its self-explanatory presentation gives engineers and system operators more efficient, precise and quick parameterization of IO-Link devices. One example is the SSC (Switching Signal Channel) setting for measuring sensors or sonic cone definition at ultrasonic sensors. This way, BSS is a popular key tool in mechanical engineering, as it communicates with all available IO-Link devices via IO-Link masters — even including those from third-party manufacturers. Baumer also offers a compact USB-C IO-Link master. There is no need for an additional power supply. The USB-C IO-Link master is an ideal interface between sensor and the PC: on the desk, during machine commissioning or in the event of service.

Example 4: IO-Link Uses Standard Cabling

Another benefit of IO-Link is simplified wiring. This means reduced cost, time savings in installation and eliminating sources of error. How does this work? First, standardized and simplified wiring prevents errors and speeds up commissioning. Further, IO-Link cuts down on costs of cabling material. Unlike bus systems, low-cost, unshielded standard cables will do for data transmission (maximum cable length 20 meters). There is no need for an analogue input card due to IO-Link Master interposition in the field. This will reduce cable length, since wiring is only required up to the IO-Link master and no longer up to the control cabinet. Via M12 connector the Master will be fitted within a few minutes, while control cabinet wiring would take hours. A Baumer example machine calculation found that the IO-Link master already pays off when being equipped with just two to three measuring sensors.

Example 5: Becoming an IO-Link Expert with a Feature-Length Film

However, the above benefits have their price: increased complexity. Compared to classic switching and analog signals, IO-Link is much more complex. But Baumer offers a smart solution for easy technology access and getting started. One solution component is the parameterization software, Baumer Sensor Suite. And, as online trainer Baumer offers further support on PLC integration. Two Baumer How-To tutorials explain PLC integration step by step in only 80 minutes: from IO-Link master setup to the integration of cyclic and acyclic data. With this starter guide on YouTube, anyone can become an IO-Link expert - within feature film length.

In addition, Baumer offers personal IO-Link training courses for in-depth technology and application know-how and understanding. The workshops consider key topics like cabling, application examples and sensor parameterization, tailored to specific fields of application. 

IO-Link Is Powering the Automation of Tomorrow

IO-Link holds application potential for smart automation, some of which is still unexplored. The complete IO-Link package from Baumer for high-speed applications enables users to fully exploit this potential and hence secure a competitive edge. From sensor to IO-Link master on to PLC and higher-level IT systems — the right cabling ensures perfect interaction. This simplifies engineering and enables data speed that allows for IO-Link application in high-dynamic packaging installations. Hence, Baumer responds to the wish of many plant operators and maintenance technicians for on-demand maintenance in packaging. Access to practical IO-Link applications is easy and won't take too much time thanks to 80-minute video tutorials with step-by-step explanations.

For More Info:
Baumer Group
Phone: +41 52 728 11 22
Fax: +41 52 728 11 44
sales@baumer.com

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