This presentation will be covering what a typical IO-Link solution consists of, how it interfaces to the control system and the benefits that can be derived from this increased level of communication with IO-Link devices. These include: easier handling of measurement signals, remote and automatic device parameterisation, smart sensor diagnostic functions, safety over IO-Link whilst also being an enabler for Industrial IoT and Industry 4.0 strategies.

1. Russell Smith
Balluff Limited
IO-Link Technology

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what is IO-link?

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not another bus system!
point to point communications protocol from the
fieldbus to the sensor and actuator level.
upto20M
Pulse-width modulated 24V
Baud rates: 4.8 kBit/s (COM1), 38.4 kBit/s (COM2), 230,4 kBits/s (COM3)
Pin Signal Description
1 L + 24 Volt
2
3 L - 0 Volt
4 C / Q
IO-Link
communication
+ switching signal

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an open standard
standard - IEC 61131-9
network neutral

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IO-Link system basic components:
IO-Link master
… acts as a gateway between the IO-Link device and the higher level communication
system, such as a fieldbus (Profinet, EtherNet/IP, etc.) or a device-specific backplane bus.
IO-Link device
… is the field device with communication capability: sensors, switching
devices, valve terminals, RFID devices, indicator lights, etc.
3-core unshielded standard cable – up to 20M long
… is the standard interface between IO-Link master and device
IODD and engineering tool
… are used to configure and assign parameters to the IO-Link system and devices.

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IO-Link devices
many different IO-Link devices are available.

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IO-Link masters
panel
mounted unit
with terminals
IP67 field I/O
module
additional slice on existing PLC

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why IO-Link?

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easier handling of measurement devices
lower cost – no analogue card
lower cost vs IE networked device
less wiring effort
traditionally
better
best

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low cost per I/O point – 496 I/O on one IP address
low cost
high density
less addresses

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extensive diagnostics
available on sensors/devices and
sensor hubs
troubleshoot problems quickly
maximise up-time

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extensive diagnostics
Short circuit – LED for each I/O port
Short circuit does not impair the unit
Sensor/actuator under voltage LED for each I/O port

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simplify valve manifold wiring
reduced installation time
reduced cost

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IO-Link safety

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extends communication
ERP
MES
SCADA
PLC
Network
Sensors and Actuators
Enterprise Level
Control Level
Management Level
Plant Control Level
Field Level
Sensor / Actuator Level

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HMI
parameterisation – std pressure sensor
HMI
HMIHMIHMI
HMI

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parameterisation – std pressure sensor
Time consuming configuration of 10 – 15 Parameter.
(e.g. upper/lower Pressure point, Hysteresis, Time – or
Pressure window)
Machine Tools have often more than 10 Pressure sensors
Error prone due to manual entry
Very bad when Sensor failure / Sensor exchange
(especially during night shift)
Manual
configuration

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parameterisation – std pressure sensor
HMI
HMI
HMI
HMI

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HMI integrated in sensor for set up
means additional cost.
Expensive high-pressure hydraulic
hoses
parameterisation – std pressure sensor
machine tool
Additional cost for protective
housing for sensors in the machine

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parameterisation – pressure sensor with IO-Link
E.g. machine tool

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PLC
Function-
blocks
Vendor_ID
Device_ID
Param1: 50bar
Param2: 100bar
Param3: 200ms
Step 1
Identify device
Step 3
Get Parameter Set
Step 2
Check identity
Step 4
Write Parameter
Set
parameterisation – pressure sensor with IO-Link

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parameterisation – pressure sensor with IO-Link
sensor installed at point of measurement
no expensive measurement cables - use std
un-shielded 3-wire standard cables
no protection case
no sensors with HMI but reliable
parameterisation via controller and HMI of
the machine
decentralised diagnostics for sensors

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parameter server
IO-Link V1.1 master

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automated tool changes
IO-Link inductive couplers for non-contact
signal transmission

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an i4.0 enabler
ERP
MES
SCADA
PLC
Network
Sensors and Actuators
Enterprise Level
Control Level
Management Level
Plant Control Level
Field Level
Sensor / Actuator Level

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unabated IO-Link success!

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how IO-Link?

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connect the master to the PLC and install the GSDML
file
drag and drop the relevant file and make the
PROFINET connection from the PLC to the master in
TIA Portal
IO-Link master configuration

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IO-Link master configuration
Drag the appropriate (process
data length) IOL input / output
byte from the catalogue and
name & address the module

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device configuration from PLC or using parameter
server
1. controller parameter storage – parameterisation
from the PLC using the function block
2. IO-Link master ver 1.1 parameter server

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device configuration with USB master or
webserver
3. Laptop via USB master (PROFIBUS) or Ethernet
using Device Manager software
4. webserver entry with IO-Link master

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device configuration with Device Manager

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device configuration with Device Manager

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device configuration with integrated web server

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device configuration with integrated web server

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device configuration - manual
Manual
configuration
5. Manual configuration

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THANKS FOR LISTENING!
Russell Smith
Product Marketing Manager Industrial Networking
+44 (0)777 331 7984
russell.smith@balluff.co.uk
www.linkedin.com/in/russellsmithindustrymanager