Use IO-Link for Increased Flexibility, Availability, and Efficiency in Industry 4.0 Factories
There are two master port classes, A and B. In class A ports, pins 2 and 5 are not connected (NC), and in class B ports, those pins can be configured as DI, DO, not connected (NC), or can provide an additional power supply. In most industrial installations, M12 quick disconnect connectors are used. A summary of the pin assignments as defined in IEC 60974-5 is shown in Figure 2: n Pin 1: +24 VDC, 200 mA maximum (L+) n Pin 2: Digital I/O (PNP only) n Pin 3: 0 volts (L-) n Pin 4: Digital I/O (NPN, PNP, or push-pull) and IO-Link communication n Pin 5: Center pin NC (optional)
n Service Data: This includes information about the device and is sometimes called device data. Service data includes device parameter values, device description, and model and serial number. It is acyclical and can be read from or written to a device as needed. n Event Data: This includes error handling and includes error messages like parameter settings being exceeded or maintenance warnings like a dirty lens on an imaging sensor. They are transmitted acyclically whenever a triggering event occurs. Remote configuration enables network operators and technicians to read and change device parameters through software control without physically going to each individual device. Sensor parameters can be dynamically changed as needed to refine existing processes, speed product and process changes, support mass customization, and minimize machine and line downtime. Simplified device replacement is enabled by the ability to remotely configure devices. The Auto Device Replacement (ADR) function in IO-Link can provide automatic parameter adjustments and reassignments for replaced devices. With ADR, network operators can import existing parameter values into a replacement device or update
How to connect IO-Link devices Devices in an IO-Link network are connected using three or five conductor unshielded cables up to 20 meters (m) long. IEC 60947-5-2 defines the master and device pin assignments. Male connectors are assigned to the device, and female connectors are used for the master. Connectors can be M5, M8, or M12 with up to five pins. At the master, 24 volts direct current (VDC) at up to 200 milliamperes (mA) is provided between pins 1 and 3 to act as an optional power supply for devices. Pin 4 is defined as a digital input (DI) or digital output (DO) based on IEC 61131-2, and it supports backward compatibility with legacy devices according to IEC60947-5-2.
Why IO-Link?
IO-Link contributes to substantial performance improvements in Industry 4.0 networks using simple device installation or replacement with standardized, reliable, and low-cost wiring. In addition, it’s designed to simplify the integration of isolated sensors into existing networks. Benefits of IO-Link include: Data availability is enabled using IO-Link to connect isolated devices and islands of automation into a unified network. Sensor-level data is not always available or easy to acquire. With IO-Link, data becomes easy to acquire and can be available in real time to optimize processes and support proactive machine and sensor maintenance. IO-Link supports three primary data types that can be further categorized as either cyclic data that is automatically transmitted on a regular schedule, or acyclic data that is transmitted upon request or as needed: n Process Data: This refers to information like sensor readings that the device transmits to the master, as well as information from the master to control device operations, like lighting specific segments on a tower lighting fixture. Process data can be cyclic or acyclic.
Figure 3: The DXMR90-4K IO-Link master device can combine data from four local sources and connect with a higher-level network. (Image source: Banner Engineering)
Getting started: IO-Link master/controller Automation system designers adding or extending the use of IO-Link can start by selecting an IO-Link master (or controller) like the DXMR90-4K from Banner Engineering that consolidates data from multiple sources, provides local data processing, and enables connectivity to the higher-level network (Figure 3). The four ports of the DXMR90- 4K support concurrent communications with up to four IO-Link devices. It supports data collection, edge processing, and protocol conversion for connection to industrial Ethernet or Modbus/ TCP, and can transfer data to web servers. Other features of the DXMR90-4K include: n Compact and lightweight housing that saves space and simplifies deployment n IP67 rating eliminates the need for a separate control cabinet, contributing to reduced installation costs
the parameters as needed to ensure rapid and accurate network modifications and maintenance. Extended diagnostics takes advantage of the cyclic and acyclic communications capabilities of IO- Link to provide network operators with extensive information about the operational status of each device in the factory. The ability to remotely diagnose device operation can speed the identification of devices that are deteriorating or operating out of specification. This allows more efficient scheduling of maintenance or device replacement. Standardized and simple wiring is a key feature of IO-Link. Unlike other network protocols, IO-Link devices, converters, hubs, and masters are all connected using simple and low-cost unshielded cables and quick disconnect connectors. The master-slave architecture of IO-Link further simplifies wiring requirements
Figure 2: IO-Link is a simple solution for providing power and data connectivity to devices at the edge like sensors and actuators. (Image source: Banner Engineering)
and eliminates network configuration concerns.
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