This document introduces IO-Link, a point-to-point communication protocol designed for connecting sensors and actuators to higher-level communication systems. It details the architecture of IO-Link systems, including components such as IO-Link devices and masters, and highlights benefits like easier device handling, reduced costs, and extensive diagnostics. The document emphasizes the importance of IO-Link in modern industrial automation and its role as an enabler for Industry 4.0.

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
13
reduced installation time
reduced cost

14. extends communication
14
ERP
MES
SCADA
PLC
Network
Sensors and Actuators
Enterprise Level
Control Level
Management Level
Plant Control Level
Field Level
Sensor / Actuator Level

15. HMI
parameterisation – std pressure
sensor
15
HMI
HMIHMIHMI
HMI

16.  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
16
Manual
configuration

17. parameterisation – std pressure sensor
17
HMI
HMI
HMI
HMI

18. HMI integrated in sensor for set up
means additional cost.
Expensive high-pressure hydraulic
hoses
parameterisation – std pressure sensor
18
machine tool
Additional cost for protective
housing for sensors in the machine

19. E.g. machine tool
parameterisation – pressure sensor with IO-Link
19

20. 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
20

21.  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
21

22. parameter server
22
IO-Link V1.1
master

23. automated tool changes
23
IO-Link inductive couplers
for
non-contact signal
transmission

24. an i4.0 enabler
24
ERP
MES
SCADA
PLC
Network
Sensors and Actuators
Enterprise Level
Control Level
Management Level
Plant Control Level
Field Level
Sensor / Actuator Level

25. unabated IO-Link success!
25

26. HOW IO-LINK?

27. 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

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

29. Drag the appropriate (process data length) IOL input / output
byte from the catalogue and name & address the module
IO-Link master configuration
29

30. 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