With an installed base approaching 4 million nodes IO-Link is THE protocol for communication down to the sensor and actuator level. 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. An Introduction to IO-Link
Russell Smith
Balluff Limited

2. WHAT IS IO-LINK?
2

3. not another bus system!
3
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

4. standard - IEC 61131-9
network neutral
an open standard
4

5. 5
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.
an IO-Link system generally consists of the following
basic components:

6. IO-Link devices
6
many different IO-Link devices are
available.

7. IO-Link masters
7
panel mounted unit
with terminals
IP67 field
I/O module
additional slice on
existing PLC

8. WHY IO-LINK?

9. easier handling of measurement
devices
9
traditionally
better
best
lower cost – no analogue
card
lower cost vs IE networked
device
less wiring effort

10. 10
low cost
high density
less addresses
low cost per I/O point – 136 I/O on one IP address

11. extensive diagnostics
11
available on sensors/devices
and sensor hubs
troubleshoot problems
quickly
maximise up-time

12. • 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
extensive diagnostics:
12

13. simplify valve manifold wiring
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reduced installation time
reduced cost

14. • World´s first combination of IO-Link
and Safety
• Communication via one Topology
• Open System on the sensor level
• Connection of the safety IO-Link
device to the standard Balluff
IO-Link-Master
• Parameterization via PLC
SAFETY OVER IO-LINK
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Balluff GmbH | BN

15. PROFISAFE IO HUB
15
Balluff GmbH | BN Safety, M. Bristle
&
Further features
• Profisafe over IO-Link
• PLe / SIL CL 3
• standardized wiring concept (AIDA)
• Diagnostic and Display integrated
• CE, TÜV, (UL in preparation)
technical data (extract)
• Cycle time: 20 ms
• Temperature range: -5°C…55°C
• Inputs: 2 pcs.
• Safe Inputs: 12 pcs.
• Outputs: 2 pcs.
• Safe Outputs: 2 pcs.
• Sum current (Aktors): 8 A
• Sum current (Sensors): 4,8 A

16. PORT CONFIGURATION
16
Balluff GmbH | BN Safety, M. Bristle
Cable length IO-Link:
max. 20 m
(acc. IO-Link Specification)
Cable length Device:
max. 30 m
(s. Specification Device)
Cable length UB:
max. 30 m

17. extends communication
17
ERP
MES
SCADA
PLC
Network
Sensors and Actuators
Enterprise Level
Control Level
Management Level
Plant Control Level
Field Level
Sensor / Actuator Level

18. HMI
parameterisation – std pressure
sensor
18
HMI
HMIHMIHMI
HMI

19. 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)
parameterisation – std pressure sensor
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Manual
configuration

20. parameterisation – std pressure sensor
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HMI
HMI
HMI
HMI

21. HMI integrated in sensor for set up
means additional cost.
Expensive high-pressure hydraulic
hoses
parameterisation – std pressure sensor
21
machine tool
Additional cost for protective
housing for sensors in the machine

22. E.g. machine tool
parameterisation – pressure sensor with IO-Link
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23. 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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24. 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
parameterisation – pressure sensor with IO-Link
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25. parameter server
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IO-Link V1.1
master

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

27. an i4.0 enabler
27
ERP
MES
SCADA
PLC
Network
Sensors and Actuators
Enterprise Level
Control Level
Management Level
Plant Control Level
Field Level
Sensor / Actuator Level

28. unabated IO-Link success!
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29. HOW IO-LINK?

30. device configuration
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1. controller parameter storage –
parameterisation from the PLC using the
function block
2. IO-Link master ver 1.1 parameter server
3. PC storage with USB master
4. webserver entry with IO-Link master
5. Manual configuration

31. IO-Link master configuration
connect the master and install GSDML file
drag and drop the relevant file

32. Drag the appropriate (process data length) IOL input / output
byte from the catalogue and name & address the module
IO-Link master configuration
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33. THANKS FOR LISTENING!