IO-Link

Safely Switch Off Cylinders While Transmitting Field Data

Guest contributor: Matthias Wolfer, Balluff

 

Is it possible to safely switch off cylinders while simultaneously transmitting field data and set up the system in accordance with standards? Yes!

In order to rule out a safety-critical fault between adjacent printed circuit board tracks/contact points (short circuit) according to DIN EN ISO 13849, clearance and creepage distances must be considered. One way to eliminate faults is to provide galvanic isolation by not interconnecting safety-relevant circuits/segments. This means  charge carriers from one segment cannot switch over to the other, and the separation makes it possible to connect the safety world with automation — with IO-Link. Safely switching off actuators and simultaneously collecting sensor signals reliably via IO-Link is possible with just one module. To further benefit from IO-Link and ensure safety at the same time, Balluff’s I/O module is galvanically isolated with a sensor and an actuator segment. The two circuits of the segments are not interconnected, and the actuator segment can be safely switched off without affecting the sensors. Important sensor data can still be monitoring and communicated.

The topological structure and the application of this safety function is shown in this figure as an example:

2D-SAGT-Betriebsanleitung_v2

  1. A PLC is connected to an IO-Link master module via a fieldbus system.
  2. The IO-Link master is the interface to all I/O modules (IO-Link sensor/actuator hubs) or other devices, such as IO-Link sensors. The IO-Link communication takes place via a standardized M12 connector.|
  3. Binary switching elements can be connected to the galvanically isolated sensor/actuator hub (BNI IOL-355). The four connection ports on the left correspond to the sensor segment and the four ports on the right correspond to the actuator segment. Communication of the states is done via IO-Link.
  4. The power supply for both segments takes place via a 7/8″ connection, whereby attention must be paid to potential separated routing of the sensor and actuator circuits. Both the power supply unit itself and the wiring to the IO-Link device with the two segments must also ensure external galvanic isolation. This is made possible by separating the lines with a splitter.
  5. An external safety device is required to safely interrupt the supply voltage of the actuator segment (four ports simultaneously). Thus, the module can implement safety functions up to SIL2 according to EN62061/PLd and ISO 13849.

For example, this can happen through the use of a safety relay, whereby the power supply is safely disconnected after actuation of peripheral safety devices (such as emergency stops and door switches). At the same time, the sensor segment remains active and can provide important information from the field devices.

The module can handle up to eight digital inputs and outputs. If the IO-Link connection is interrupted, the outputs assume predefined states that are retained until the IO-Link connection is restored. Once the connection is restored, this unique state of the machine can be used to continue production directly without a reference run.

An application example for the interaction of sensors and actuators in a safety environment is the pneumatic clamping device of a workpiece holder. The position feedback of the cylinders is collected by the sensor segment, while at the same time the actuator segment can be switched off safely via its separately switchable safety circuit. If the sensor side is not required for application-related reasons, galvanically isolated IO-Link modules are also available with only actuator segments (BNI IOL 252/256). An isolated shutdown can protect up to two safety areas separately.

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Robot Collaborative Operation

Guest contributor: Tom Knauer, Balluff

In previous blogs, we discussed how “Safety Over IO-Link Helps Enable Human-Robot Collaboration” and “Safety & Productivity”. We’ll build on these blogs and dive more deeply into two robot collaborative operating modes: Safety-Rated Monitored Stop (SRMS) and Speed & Separation Monitoring (SSM).

Human-Robot Collaboration

Human-robot collaboration has received a lot of attention in the media, yet there is still confusion about the meaning and benefits of various types of collaboration. In a previous blog we briefly discussed the four collaborative modes defined by the global standard ISO/TS 15066. The most well-known mode is “power & force limiting”, which includes robots made by Universal Robots and Rethink. As the name implies, these robots are designed with limited power and force (and other ergonomic factors) to avoid injury or damage, but they are also slower, less precise and less powerful than traditional robots, reducing their usefulness in many common applications.

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The safety-rated monitored stop (SRMS) and speed & separation monitoring (SSM) modes are very interesting because they allow larger, more powerful, traditional robots to be used collaboratively — though in a different manner than power & force limited robots. The updated standards allow the creation of a shared workspace for the robot and human and define how they may interact in this space. Both SRMS and SSM require this shared workspace to be monitored using advanced safety sensors and software, which create a restricted space and a safeguarded space. With SRMS, the robot stops before the operator enters the collaborative workspace — this requires a safety sensor to detect the operator. Similarly, in SSM the goal is to control the separation distance between the human and robot, but it can be dynamic, rather than static as in SRMS. The SRMS separation distance can never be less than the protective distance and this requires sensors to verify the separation.

Spaces

The robot’s restricted space is a 3-dimensional area created to limit where the robot can operate. In the past this was done through limit switches, hard stops or sensors such as Balluff’s BNS; now the standards have been updated to allow this to be done in software with internal robot feedback that can dynamically change to adapt to the robot’s programmed operation. The robot controller can now restrict the robot’s motion to a specific envelope and monitor its actual position against its programmed position within this envelope using software tools such as Safe Move or Dual Check Safety.

The safeguarded space is defined and monitored using safety sensors. The robot might know and assure its own safe position within the restricted space, but it doesn’t know whether or not a person or obstruction is in this space, therefore a safeguarded space needs to be created using safety sensors. Advanced sensors not only detect people or obstructions, but can also actively track their position around the robot and send warning or stop signals to the safety controller and robot. Safety laser scanners, 3D safety cameras and other safety sensors can create zones, which can also be dynamically switched depending on the operating state of the robot or machine.

Closely coordinating the restricted space and safeguarded space creates a flexible and highly productive system. The robot can operate in one zone, while an operator loads/unloads in a different zone. The robot sensors monitor the restricted space while the safety sensors monitor the safeguarded space – and when the robot moves to the next phase of operation, these can dynamically switch to new zones. Warning zones can also be defined to cause the robot can slow down if someone starts to approach too closely and then stop if the person comes too close.

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System Linkages

Linking the restricted space and safeguarded space to create an effective, closely coordinated human-robot SSM/SRMS collaborative system requires several elements: a high performance robot and controller with advanced software (e.g. Safe Move), a fieldbus and a variety of built-in and external sensors (standard and safety).

Significant growth in robot collaborative applications utilizing safety-rated monitored stop (SRMS) and speed & separation monitoring (SSM) will occur as robot users strive to improve productivity and safety of traditional robot systems – especially in applications requiring faster speed, higher force and more precision than that offered by power & force limited robots.

To learn more visit www.balluff.com

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Changing the Paradigm from Safety vs. Productivity to Safety & Productivity

Guest Contributor: Tom Knauer, Balluff

In a previous blog, we discussed how “Safety Over IO-Link Helps Enable Human-Robot Collaboration”. It was a fairly narrow discussion of collaborative robot modes and how sensors and networks can make it easier to implement these modes and applications. This new blog takes a broader look at the critical role safety plays in the intersection between the machine and the user.

In the past, the machine guarding philosophy was to completely separate the human from the machine or robot.  Unfortunately, this resulted in the paradigm of “safety vs. productivity” — you either had safety or productivity, but you couldn’t have both. This paradigm is now shifting to “safety & productivity”, driven by a combination of updated standards and new technologies which allow closer human-machine interaction and new modes of collaborative operation.

Tom_Safety1.pngThe typical machine/robot guarding scheme of the past used fences or hard guards to separate the human from the machine.  Doors were controlled with safety interlock switches, which required the machine to stop on access, such as to load/unload parts or to perform maintenance or service, and this reduced productivity.  It was also not 100% effective because workers inside a machine area or work cell might not be detected if another worker restarted the stopped machine.  Other drawbacks included the cost of space, guarding, installation, and difficultly changing the work cell layout once hard guarding had been installed.

We’ve now come to an era when our technology and standards allow improved human access to the machine and robot cell.  We’re starting to think about the human working near or even with the machine/robot. The robot and machinery standards have undergone several changes in recent years and now allow new modes of operation.  These have combined with new safety technologies to create a wave of robot and automation suppliers offering new robots, controllers, safety and other accessories.

Standards
Machine and robot safety standards have undergone rapid change in recent years. Standard IEC 61508, and the related machinery standards EN/ISO 13849-1 and EN/IEC 62061, take a functional approach to safety and define new safety performance levels. This means they focus more on the functions needed to reduce each risk and the level of performance required for each function, and less on selection of safety components. These standards helped define, and made it simpler and more beneficial, to apply safety PLCs and advanced safety components. There have also been developments in standards related to safe motion (61800-5-2) which now allow more flexible modes of motion under closely controlled conditions. And the robot standards (10218, ANSI RIA 15.06, TS15066) have made major advances to allow safety-rated soft axes, space limiting and collaborative modes of operation.

Technology
On the technology side, innovations in sensors, controllers and drives have changed the way humans interact with machines and enabled much closer, more coordinated and safer operation. Advanced sensors, such as safety laser scanners and 3D safety cameras, allow creation of work cells with zones, which makes it possible for an operator to be allowed in one zone while the robot performs tasks in a different zone nearby. Controllers now integrate PLC, safety, motion control and other functions, allowing fast and precise control of the process. And drives/motion systems now operate in various modes which can limit speed, torque, direction, etc. in certain modes or if someone is detected nearby.

Sensors and Networks
The monitoring of these robots, machines and “spaces” requires many standard and safety sensors, both inside and outside the machine or robot. But having a lot of sensors does not necessarily allow the shift from “productivity vs. safety” to “productivity & safety” — this requires a closely coordinated and integrated system, including the ability to monitor and link the “restricted space” and “safeguarded space.” This is where field busses and device-level networks can enable tight integration of devices with the control system. IO-Link masters and Safety Over IO-Link hubs allow the connection of a large number of devices to higher level field busses (ProfiNet/ProfiSafe) with effortless device connection using off-the-shelf, non-shielded cables and connectors.

Balluff offers a wide range of solutions for robot and machine monitoring, including a broad safety device portfolio which includes safety light curtains, safety switches, inductive safety sensors, an emergency stop device and a safety hub. Our sensors and networks support the shift to include safety without sacrificing productivity.

To learn more about Safety over IO-Link, visit www.balluff.com

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

What Exactly is Safety Over IO-Link?

Automation Pyramid.png

This integrated safety concept is the logical continuation of the IO-Link philosophy. It is the only globally available technology to build on the proven IO-Link standards and profisafe. This means it uses the essential IO-Link benefits such as simple data transport and information exchange, high flexibility and universal applicability for safety signals as well. Safety over IO-Link combines automation and safety and represents efficient safety concepts in one system. Best of all, the functionality of the overall system remains unchanged. Safety is provided nearly as an add-on.

In the center of this safety concept is the new safety hub, which is connected to an available port on an IO-Link master. The safety components are connected to it using M12 standard cable. The safety profisafe signals are then tunneled to the controller through an IO-Link master. This has the advantage of allowing existing infrastructure to still be used without any changes. Parameters are configured centrally through the user interface of the controller.

Safety Hub

The safety hub has four 2-channel safe inputs for collecting safety signals, two safe outputs for turning off safety actuators, and two multi-channel ports for connecting things like safety interlocks which require both input and output signals to be processed simultaneously. The system is TÜV- and PNO-certified and can be used up to PLe/SIL 3. Safety components from all manufacturers can be connected to the safe I/O module.

Like IO-Link in general, Safety over IO-Link is characterized by simple system construction, time-and cost-saving wiring using M12 connectors, reduction in control cabinet volume and leaner system concepts. Virtually any network topology can be simply scaled with Safety over IO-Link, whereby the relative share of automation and safety can be varied as desired. Safety over IO-Link also means unlimited flexibility. Thanks to varying port configuration and simple configuration systems, it can be changed even at the last minute. All of this helps reduce costs. Additional savings come from the simple duplication of (PLC-) projects, prewiring of machine segments and short downtimes made possible by ease of component replacement.

Development of IO-Link, number of sold nodes.png

To learn more about Safety over IO-Link, visit www.balluff.com

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Hydraulics with IO-Link: Reduced effort, high value

Guest contributor: Theobald Herrmann, Bosch Rexroth

In almost all industries, machine users require increased flexibility for production means for small batches and continuous diagnostics of all actuators and sensors to increase availability. In addition to this, there is quickly increasing horizontal and vertical connection of machinery and systems for Industry 4.0 applications. The open standard IEC 61131-9, IO-Link, fulfills these requirements at low connection costs and energy consumption. Flexibility of hydraulics is increased by transmission of parameter changes in running operation. Provision of diagnostics information offers numerous opportunities to extend the concepts of predictive maintenance to increase availability of the systems. The manufacturer-independent IO-Link can be integrated easily and quickly in any industrial automation application.

Standardized wiring and electronic name plate support commissioning and increase availability

• Open standard for bi-directional point-to-point connections in parallel to field bus
• Easy connection with standard cables and M12 connectors
• No additional engineering tool necessary, possible configuration via control system.
• Data for predictive maintenance and quick device replacement
 Industry 4.0-compatible hydraulic components for vertical flow of information

Introduction: Limits of serial field bus communication

The introduction of field bus technology in the 1980s was the starting point for horizontal connection of decentralized actuators within machinery. Serial wiring lead to a considerable reduction in cabling and opened new possibilities for modularization in mechanical engineering. Field buses as well as most current real-time Ethernet protocols are manufacturer-specific, proprietary systems. The protocols have been developed by control system manufacturers and focus on communication between own electric control systems and selected peripherals. For actuators, sensors and other third-party equipment, either their manufacturers or system integrators are required to provide suitable interfaces in hardware and software for the respective field bus. This is very complex as device profiles and software have to be created in the respective PLC for every individual field bus and control system of each manufacturer.

Possibilities for hydraulic connection

Integration of hydraulics in modern automation systems can be realized in different ways. Numerous existing machine concepts apply on-board electronics for control of hydraulic valves. Exchange of digital information is restricted and only possible if the respective device is connected to a superior control system via individual wiring. This state-of-the-art in technology increasingly no longer meets the requirements of end users.

The alternative are valves with integrated field bus connection. These, however, require extensive wiring as well as integration into the control system and the respective field bus protocol by means of dedicated software. Both requires considerable effort that is too high particularly for price-sensitive applications.

Thanks to IO-Link, machine manufacturer and system integrators are enabled to integrate for example proportional hydraulic series valves and sensors into digital communication structures with very little engineering effort. With its simple communication structure, IO-Link has low hardware requirements. Additionally, the standardized M12 connection technology enables simple and cost-efficient connection of hydraulic valves in the field. This way, previously “deaf-mute” components with analog control are transformed in communicating and flexible actuators and sensors.

IO-Link: Manufacturer-independent and compatible with all field bus protocols

The manufacturer-independent IO-Link according to IEC 61131-9 standardizes connection technology for actuators, sensors and other equipment and provides a digital communication protocol for data exchange between control systems and devices regardless of the field bus. Field bus technology is not replaced but extended. Parallel communication enables machine manufacturers use of IO-Link with all protocols and integration of IO-Link-compatible devices into various concepts without additional effort.

IO-Link is currently already supported by around 130 device manufacturers and companies in the field of technology. Around 40 manufacturers offer IO-Link Masters and the standard is supported by nine manufacturers of control systems with central Masters and respective engineering tools. IO-Link devices are in the product range of almost sixty manufacturers of sensors, actuators and other peripherals. Rexroth, for example, now also offers hydraulic proportional valves and pressure sensors with respective technology. Function and performance of these proportional valves are identical to series valves. However, they also offer all options for bi-directional communication via IO-Link. This way, the hydraulics can be integrated seamlessly into connected structures. Parameters can be changed and operating states changed by the control system during running operation.

IO-Link system set-up

A full IO-Link system consists of one centralized or decentralized IO-Link Master, one or more IO-Link devices as well as unshielded 3 or 5-conductor standard cables with M12 connectors. Project planning and parameterization of the IO-Link Master can be realized in the control system hardware or an optional engineering tool. The point-to-point connections between IO devices and the automation system are established by the Master. It serves as the interface to the superior control system.

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IO-Link Masters are offered by around 50 manufacturers for connection of one IO device per port. The selection includes options for the IP20 control cabinet as well as decentralized modules with protection class IP65/67 for installation at machinery. Particularly in large-scale systems, cabling is considerably reduced.

For decentralized IO-Link Masters, the user organization of IO-Link has defined M12 plug-in connectors with three or five conductors. The 5-pole version “Class B” port is used for devices with increased current consumption like hydraulic valves. The 3-pole version “Class A” port provides an energy supply of up to 200 mA which is sufficient for most sensors. In contrast to analog controls, unshielded cables are sufficient for fault-free communication over a cable length of up to 20 meters. IO-Link standardizes connection technology for all actuators and sensors and eliminates numerous sources of errors during the installation of systems. Otherwise complicated and expensive cable dimensioning with individual wiring and shielding is no longer required. In addition, the logistic effort is reduced thanks to application of uniform M12 cables for sensors and actuators.

Rapid commissioning per software

Every IO-Link device features an electronic device description, referred to as IO Device Description (IODD). It provides standardized important information:

• Device data
• Text description
• Identification, process and diagnosis data
• Communication properties
• Device parameters with value range and default value.
• Image of the device
• Logo of the manufacturer

The IODD set-up is identical for all devices of all manufacturers. The IODD enables automatic recognition of the device by the IO-Link Master for immediate parameterization. Also automatically, device descriptions are included in the system documentation.

For project integration of the IO-Link Master in overall automation, commissioning personnel use the engineering tools of the respective PLC manufacturer. The IO-Link Master is selected from the device portfolio and added to overall automation. Depending on the control system manufacturer, all blocks for communication are available in a library for free.

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Via IO-Link to Industry 4.0

IO-Link enables access to device data either directly from the control system or remotely via networks from any location. Particularly important for future-oriented concepts: Already today, IO-Link offers type and instance data of Industry 4.0 devices according to the definition of the German “Plattform Industrie 4.0” initiative.

This way, also hydraulic actuators meet all conditions for future requirements of Industry 4.0 applications. Additionally, this approach is well-suited for subsequent connection of existing machinery and systems with low effort. Users replace installed proportional valves and sensors by interchangeable options with IO-Link connection for direct communication with actuators and sensors.

Diagnosis functions for increased availability

The diagnosis functions of IO-Link devices enable new maintenance concepts and considerably reduce repair times. Now possible call-up of device information in parallel to the process forms the basis for condition-oriented and predictive maintenance concepts. In this respect, proportional valves report whether they are functional as well as errors like under or overvoltage. In addition, the valve and sensor status is displayed for transparent error analysis. An integrated operating hour indicator enables calculation of the residual life-cycle for maintenance and decision-making on further use of the valve.

In case of faults, IO-Link accelerates diagnosis thanks to remote access for maintenance specialists to identify the type and location of any errors. Precise localization without personal presence at the system alone considerably reduces reaction times. If necessary, the maintenance technician opens the IODD file of the respective device in the control system. Other than before, components do not need to be disassembled to decipher hardly readable labels and manufacturers and types no longer need to be looked for in system documentations. Thanks to the electronic name plate, all this information can now be accessed with just one mouse click to initiate the respective order without delay.

IO-Link follows the plug & play principle. Replaced devices are recognized by the IO-Link Master according to their IODD file and the respective parameters are automatically transferred without any actions in the software. This way, even less experienced technicians are enabled to replace components without problems to considerably reduce system downtimes.

Summary

The open IO-Link standard establishes continuous communication with sensors and actuators irrespective of the used field bus. Now, even hydraulic proportional valves can be intelligently, easily and cost-effectively integrated in bi-directional digital communication. This simplifies commissioning in hardware and software and enables flexible adjustment of hydraulic valves for varying production processes. Increased requirements for flexible machinery and systems are now complied with. Extended diagnosis information enables condition-oriented and predictive maintenance concepts and standstill and maintenance times are reduced. This increases the availability of machinery. In addition, IO-Link enables future-proof integration of hydraulic valves into connected structures as Industry 4.0 components with all their related features.

Why hydraulics and IO-Link? Click here

Learn more about Rexroth and IO-Link

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

 

Back to the Basics: What is the Value of IO-Link?

Guest Contributor: Will Healy III, Balluff

IO-Link

With the demands for flexible manufacturing, efficient production & visibility in our factories, smart manufacturing is driving the way we work today.  Analytics and diagnostics are becoming critical to our ability to perform predictive maintenance, improve equipment effectiveness and monitor the condition of the machine as well as the components inside the machine.  Typically, our first reaction is to put these devices onto Ethernet.  However, the implementation of Ethernet requires a high skill set that is scarce in our traditional manufacturers today.  Due to the simple control architecture of IO-Link devices, it allows for many Smart devices to provide the data we need for analytics with a reduction in the Ethernet skill set that has become a roadblock for many manufacturers.

Many people think IO-Link is a new industrial network to compete with EtherNet/IP or Profinet, but this is a common misconception. IO-Link is complementary to those networks and typically enables those networks to do even more than previously thought.

Standard IO-Link Setup_01_preview

Open Standard

IO-Link is an open standard designed with the idea to act like USB for industrial automation.  IO-Link is meant to simplify the smart sensor & intelligent device connectivity on the factory floor in a similar way that USB simplified connectivity to computers for auxiliary devices.  IO-Link is not an industrial network or fieldbus; it is an industrial network and industrial controller agnostic. Designed with a master to slave configuration, addressing of the devices is point-to-point, similar to USB.  Compatible IO-Link masters can act as slaves or nodes on a variety of industrial protocols and act complementary to the network of the user’s choosing.  Eliminating the need for serial communication configuration or network addressing simplifies the connection and integration of devices.

Value in Machine Builds

IO-Link has advantages for both machine io-link master_18x18_300dpibuilders and discrete manufacturers.  For machine builders, the biggest advantage comes from the simplified wiring scheme of IO-Link devices.  We have seen machine builder users of IO-Link reduce their wiring hardware & labor costs by 30%-60% for sensors,
outputs & controls.  This is realized with the simple sensor tool cords used for connections, quick-disconnect connectors on the cables and machine mount Ethernet masters devices.  It is also realized for machine builders in an increase of turns on their floor, a reduction in build labor and significantly faster commissioning time.

Value on the Production Floor

For discrete manufacturers, the biggest advantages have come from the parameterization and diagnostic features on the IO-Link devices.  With the ability to store & send parameters between the master & slave, IO-Link devices can be automatically configured. Hot-swapping a complex smart device like a pressure sensor can go from a stressful ordeal including 14-plus setpoints to literally a push of one button.  Combining this functionality with multiple diagnostics both in the master & slaves eliminates human error and dramatically reduces downtime & troubleshooting for manufacturers.

To learn more about market leading IO-Link technologies, visit www.balluff.com.

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Boost Size-Change Efficiency with IO-Link Magnetic Encoders and Visualization

Guest contributor: Henry Menke, Balluff

In many industries, especially in Packaging, the need to minimize capital equipment costs drives engineers to implement low-cost, manual methods of size change (also called format change) on their machinery. In most cases, this means hand-driven cranks with mechanical dial pointers and/or mechanical revolution counters.

While cost is saved on the procurement side, cost is also shifted over to the operational side. Plant management is left with the task of keeping accurate records of various machine set-ups needed to run different products, as well as the task of training machine operators to perform all machine set-ups correctly. It doesn’t always go as smoothly as expected, and machine reformatting can result in longer downtime than planned, machine stoppages, and possibly excessive scrap.

The key to size-change improvement is capturing the linear movements of the machine components and bringing them into the control system, and then providing “smart” visual feedback to the machine operator during setup. For capturing machine position, a robust and cost-effective magnetic linear encoder is ideal. However, traditional linear encoders deliver an A-B quadrature incremental signal, which requires re-homing upon start-up or after a power loss. What’s needed is an absolute encoder signal, but that brings other challenges such as the cost and complexity of implementing an absolute signal like SSI (Synchronous Serial Interface).

Fortunately, there’s a new encoder interface BML SL1 Absolute Magnetic Encoder with IO-Linkoption that eliminates the problem of non-absolute feedback and the hassle of absolute position signal interface: IO-Link. IO-Link is a multi-vendor, non-proprietary, device-level serial digital interface that can be aggregated onto today’s Ethernet industrial networks. Magnetic linear encoders are now available that feature absolute position indication combined with the ease and convenience of the IO-Link communication protocol.

Now we just need to provide visual feedback to the machine operator regarding which direction and how far to turn the hand cranks. Once smartlight_18x18_300dpiagain, IO-Link provides the answer in the form of an IO-Link-enabled, fully programmable multi-segment LED stack light. When a new machine set up is required, the position parameters are stored in the controller. The controller communicates over IO-Link to the LED stack lights, indicating to the operator which dials need to be turned and in which direction. For example, a horizontally mounted stack light could be lit red on the right half, indicating that the dial needs to be turned to the right. As the position moves closer to the proper setting, the red segments count down until the entire stack light goes green, indicating that the correct position for that axis has been reached. No paper records to maintain and store, and very little training required with the intuitive operator visualization.

For more information about IO-Link linear encoders click here, and to learn more about IO-Link programmable LED stack lights visit www.balluff.com.

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.