What is IO-Link 

IO-Link is a short distance, bi-directional, digital, point-to-point, wired (or wireless), industrial communication bus.

An IO-Link system consists of an IO-Link master and one or more IO-Link devices, i.e. Sensors or Actuators, or any other automation component. The IO-Link master provides the interface to the higher- level controller (PLC) and controls the communication with the connected IO-Link devices.

IO-Link makes any dumb device like sensor, actuator, hub, mechatronic component, power supply unit, or any device which is part of automation, a smart device, capable of Industry 4.0

Intelligent with regard to IO-Link means that a device has identification data, parameter data which can be changed by PLC, diagnostic data generated using AI/ ML, (Artificial Intelligence and Machine learning) for predictive maintenance, Event data which is very useful for fault analysis.

The advantages of IO-Link can be summarised as under.

  1. Increased data availability for AI / ML processing.
  2. Reduced wiring up to PLC.
  3. Remote and online configuration.
  4. Simple replacement.
  5. Extended diagnostic for future application.
  6. Data storage for fault analysts, predictive maintenance.
  7. No special cabling required for analog signals.

Why you need it 

If you are a manufacturer of sensor, actuators or any component of automation setup then you must have heard Industry 4.0.The more talk there is about Industry 4.0, the more IO-Link is also becoming a hot topic.

Interest in IO-Link has been gathering pace considerably in the wake of Industry 4.0. Users today implementing IO-Link have already fulfilled the basic requirements for a fully automated factory. The possibility to implement the forwarding of sensor data to higher-level Enterprise Resource Planning (ERP) systems is as such already in place with IO-Link. For a new technology to be established, suppliers must offer in their portfolio components for all levels of the automation pyramid. This has now become the case with IO-Link.

IO-Link is not just gaining increasing acceptance in an ever greater number of applications – the manufacturer-independent communication technology is also an enabler for innovative sensor solutions and supports the global availability of data and information required by Industry 4.0. Switching devices and simple sensors, in particular, can benefit from this fast and cost-effective method of connecting to the data world,

The advantages of IO-Link are readily apparent. Because devices can be integrated via the existing cabling, IO-Link enables Industry 4.0 solutions like cloud connectivity, predictive maintenance, truly smart sensors to be expanded down to even the smallest inductive sensors.

Flexibility, transparency, and reduced costs

Process data, parameter settings, and detailed diagnostic data via the existing connection: Sensors with an IO-Link interface can supply a wealth of information – in real time. They are also capable, for example, of receiving new parameter sets within seconds – for flexible production right down to a batch size of 1. IO-Link offers continuous digital data transmission, thus superseding the classical method of analog value transmission. It also has significant advantages with regard to electromagnetic compatibility as it also allows standard non-shielded cables to be used, thereby reducing cabling costs.

IO-Link also makes plug and play a reality: The different parameter settings can be visualized, tested, and, if necessary, optimized during integration and commissioning. Furthermore, it is possible to store different parameter sets in the automation system and upload them to the sensor during operation without any delay. This makes it possible to automatically and remotely configure sensors installed in locations that are difficult to access. Machines and plants with frequent changeovers between product variants can particularly benefit from this functionality, which enables changeovers to be performed quickly and with a high level of process reliability. Replacing devices also becomes easier: If a sensor is defective, the most recently used parameter set can be automatically transmitted to the replacement sensor via IO-Link.

Who are we

We are a manufacturer of affordable, low cost, fully customized, loaded with device stack, IO-Link modules which can fit inside any device and impart IO-Link capability to the device. This affordable module has all the necessary things in place like, M12- 4 Pin connector, 32 bit Microprocessor, efficient IO-Link PHY, Non volatile memory, and  different types of Input / Output signal to which you can connect your device. Moreover it also supports microbus like I2c, SPI, RS232, RS485 etc. The module is loaded with device stack which is fully compliant with IO-Link specification specification 1.1 and 1.0. The module supports data storage and  online firmware upgrade also. The module has artificial intelligence and machine learning capabilities, to make it fully compatible with industry 4.0.

Our service include,

  1. Study of your device like sensor, actuator, encoder, ac drive, power supply, I/O card etc.
  2. Identify the parameters to be used, and process the data with menu and teach function.
  3. Create a suitable IODD file for your device.
  4. Modify the module hardware and software as required by your device.
  5. Get vendor registration for IO-Link for consortium and compliance test certificate/
  6. Regularly supply ready built modules which can  fit inside your device.

Technology

The module consists of a small PCB mounted on M12 connector. The PCB has a powerful Arm® Cortex®-M0+ based processor, tied to power efficient IO- Link PHY, and Non Volatile RAM, multiple pins for connecting user signals. The module comes with Full functional, highly customised IO-Link stack which  supports all IO-Link functionality according to specification 1.1. The stack uses DMA (dynamic memory access) for packet transfer with IO-Link PHY, virtually freeing microprocessor from routine task, so that microprocessor can comfortably run Artificial Intelligence and Machine learning Algorithm.

Hardware Features

  1. M12, 4 pin Connector, connected to 15X35 pub Can be housed in M18 pipe.
  2. Full functional pins (C/Q and I/O)
  3. Arm® Cortex®-M0+ based processor
  4. 32MB Flash, 8Kb RAM
  5. Fully IO-Compliant PHY supporting all baud rate.
  6. 1Kb Non Volatile RAM
  7. Module supports all baud rate and cycle time of .4 mil sec.
  8. DMA ( Dynamic Memory Access) transfer for communication, sensor, analog signal etc.
  9. Multiple signal are accepted like, digital input, analog input, 4-20 ma, i2C, SPI bus
  10. Module can generate digital output, analog outputs, pwm pulses, 4-20 ma loop.
  11. Independent pin  I/Q and C/Q for Input / Output.

Software Features.

The software runs a fully compliant IO-Link stack with Data storage and Firmware upgrade. Beside IO-Link stack, the software also supports,

  1. Temperature monitoring, minimum  and maximum value recording, time integrated thermal value to determine sensor degrading, life expectancy, early failure warning.
  2. Voltage monitoring,  minimum  and maximum value recording, overvoltage stress detection, loose contact detection, under voltage safe safe shutdown, voltage fluctuation detection.
  3. Vibration detection, history recording, early warning for mechanical failure. Sensor orientation detection, sabotage detection,
  4. Power on/off cycle detection, life cycle counting, essential to determine life expectancy of sensor. Life cycle operation time in hours.
  5. Based on the above data and using artificial intelligence,  generate predictive maintenance warning, to avoid costly breakdowns.
  6. Histogram of analog signal, minimum, maximum average value, storage of last 100 readings helps in fault finding, time integrated counter, life cycle values.
  7. Pulse counting of digital signal, time between pulse, rate counter.