IO-Link

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.

IO-Link Measurement Sensors Solve Application Challenges
Guest contributor:  Scott Rosenberger, Balluff

In industrial distance and position measurement applications, one size definitely does not fit all.  Depending on the application, the position or distance to be measured can range from just a few millimeters up to dozens of meters.  No single industrial sensor technology is capable of meeting these diverse requirements.

Fortunately, machine builders, OEM’s and end-users can now choose from a wide variety of IO-Link distance and position measurement sensors to suit nearly any requirement.  In this article, we’ll do a quick rundown of some of the more popular IO-Link measurement sensor types.

(For more information about the advantages of IO-Link versus traditional analog measurement sensors, see the following blog posts, Solving Analog Integration Conundrum, Simplify Your Existing Analog Sensor Connection, and How Do I Make My Analog Sensor Less Complex?)

Short Range Inductive Distance Sensors

These sensors, available in tubular and blockScott Image1.JPG style form factors are used to measure very short distances, typically in the 1…5 mm range.  The operating principle is similar to a standard on/off inductive proximity sensor.  However, instead of discrete on/off operation, the distance from the face of the sensor to a steel target is expressed as a continuously variable value.  Their extremely small size makes them ideal for applications in confined spaces.

Inductive Linear Position Sensors

Inductive linear position sensors are available in several block style form factors, and are used for position measurement over stroke lengths up to about 135 mm.  These types of sensors use an array of inductive coils to accurately measure the position of a metal target.  Compact form factors and low stroke-to-overall length factor make them well suited for application with limited space.

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Magnetostrictive Linear Position Sensors

IO-Link Magnetostrictive linear position sensors are available in rod style form factors for hydraulic cylinder position feedback, and in external mount profile form factors for general factory automation position monitoring applications.  These sensors use time-proven, non-contact magnetostrictive technology to provide accurate, absolute position feedback over stroke lengths up to 4.8 meters.

Laser Optical Distance Sensors

 

Scott Image 4.JPGLaser distance sensors use either a time-of-flight measuring principle (for long range) or triangulation measuring principle (for shorter range) to precisely measure sensor to target distance from up to 6 meters away.  Laser distance sensors are especially useful in applications where the sensor must be located away from the target to be measured.

 

Magnetic Linear Encoders

IO-Link magnetic linear encoders use an absolute-codedScott Image 5flexible magnet tape and a compact sensing head to provide extremely accurate position, absolute position feedback over stroke lengths up to 8 meters.  Flexible installation, compact overall size, and extremely fast response time make magnetic linear encoders an excellent choice for demanding, fast moving applications.

IO-Link Measurement Sensor Trends

The proliferation of available IO-Link measurement sensors is made possible, in large part, due to the implementation of IO-Link specification 1.1, which allows faster data transmission and parameter server functionality.  The higher data transfer speed is especially important for measurement sensors because continuous distance or position values require much more data compared to discrete on/off data.  The server parameter function allows device settings to be stored in the sensor and backed up in the IO-Link master.  That means that a sensor can be replaced, and all relevant settings can be downloaded from master to sensor automatically.

To learn about IO-Link in general and IO-Link measurement sensors in particular, 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.

Imagine the Perfect Photoelectric Sensor

Guest contributor: Jack Moermond, Balluff

Photoelectric sensors have been around for a long time and have made huge advancements in technology since the 1970’s.  We have gone from incandescent bulbs to modulated LED’s in red light, infrared and laser outputs.  Today we have multiple sensing modes like through-beam, diffuse, background suppression, retroreflective, luminescence, distance measuring and the list goes on and on.  The outputs of the sensors have made leaps from relays to PNP, NPN, PNP/NPN, analog, push/pull, triac, to having timers and counters and now they can communicate on networks.

The ability of the sensor to communicate on a network such as IO-Link is now enabling sensors to be smarter and provide more and more information.  The information provided can tell us the health of the sensor, for example, whether it needs re-alignment to provide us better diagnostics information to make troubleshooting faster thus reducing downtimes.  In addition, we can now distribute I/O over longer distances and configure just the right amount of IO in the required space on the machine reducing installation time.

IO-Link networks enable quick error free replacement of sensors that have failed or have been damaged.  If a sensor fails, the network has the ability to download the operating parameters to the sensor without the need of a programming device.

With all of these advancements in sensor technology why do we still have different sensors for each sensing mode?  Why can’t we have one sensor with one part number that would be completely configurable?

BOS21M_Infographic_112917

Just think of the possibilities of a single part number that could be configured for any of the basic sensing modes of through-beam, retroreflective, background suppression and diffuse. To be able to go from 30 or more part numbers to one part would save OEM’s end users a tremendous amount of money in spares. To be able to change the sensing mode on the fly and download the required parameters for a changing process or format change.  Even the ability to teach the sensing switch points on the fly, change the hysteresis, have variable counter and time delays.  Just imagine the ability to get more advanced diagnostics like stress level (I would like that myself), lifetime, operating hours, LED power and so much more.

Obviously we could not have one sensor part number with all of the different light sources but to have a sensor with a light source that could be completely configurable would be phenomenal.  Just think of the applications.  Just think outside the box.  Just imagine the possibilities.  Let us know what your thoughts are.

To learn more about photoelectric sensors, 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.

Demystifying Class A and Class B Type IO-Link Ports
Guest contributor:  Shishir Rege, Balluff

Since the inception of the Class (or Type) A and Class (or Type) B ports in the IO-Link specifications, there have been several new IO-Link devices and IO-Link masters introduced to the market. This has caused a lot of confusion about when and where to use Class A and Class B IO-Link masters and devices.

Before getting into the details of Class A vs. Class B, I would like to address one question that I get asked quite often: are Class B master ports safety-rated? The answer is no. Just like any other network I/O modules (with the exception of the Safety I/O modules), any type of IO-Link master (whether it is Class A, Class B or mixed) is not safety rated. If the block is safety-rated, I am certain that the manufacturers of these blocks will kindly let you know. So, we just busted the first myth about Class B ports. Side note: the IO-Link Consortium just released a specification for IO-Link Safety. At the time of this posting (Oct. 2017), there are no IO-Link masters on the market that are safety rated, even when the IO-Link master ports exist alongside Safety I/O parts on the same block.

Capture.JPG

For IO-Link communication, only pins 1, 3 and 4 have significance. The implementations of pin 2 and 5 is where Class A and Class B ports differ and with that, the advantages and disadvantages of the uses for these ports.

Clearly, with the wiring diagrams above, a Class A port offers more flexibility in terms of additional I/O count and in some cases high-amperage outputs to drive high-current devices such as valves.  We will discuss the detailed power routing and application flexibility of Class A ports in a later blog.

With Class B ports, Pin 2 and Pin 5 are tied to a separate power source and cannot really be used as I/O.  Pin 5, the ground for output power, is separated from pin 3, the ground for device power. Actuation devices, such as valve banks, that are now offered on IO-Link could utilize separate output power that can be turned off through safety relays. Technically, this separation of power is possible with Class A ports as well, but it is inherent with Class B ports.

A word of caution when implementing I/O architectures with Class B masters: since the commons for device power and output power are isolated at the master, the power fed to this device should be isolated at the source as well to keep the isolation intact. That means, the power supplies feeding the power to these devices should be isolated.

Another question that I get asked frequently reveals another myth about Class B master ports: do Class B master ports offer any extra power than Class A ports? Again the answer is no. Class B does not mean extra power or the ability to provide more power. It simply means output power with isolated commons. What leads to that thinking is that on several IO-Link masters in the market, the outputs available on pin 2 of Type A ports have lower amperage ratings, because in most cases the output power is shared or drawn from the same source that feeds device power.  There will be more discussion about this in my next blog!

A third interesting question is, can you plug Class A IO-Link devices into Class B master ports? In most cases there is no problem doing this as a true IO-Link Class A device is only a 3 pin device using pins 1,3, and 4 shown above. So as long as pin 2 of the device does not exist or is not being used for any purpose, it is possible to use Class A devices with Class B ports. Caution: several manufacturers make sensors that can be used in IO-Link mode as well as analog or digital mode and the implementation may have more than 3 pins. In these circumstances, you will need to use a 3-pole cable to keep the device unharmed or the pin 2 of the type B port that always has +24V going through may damage or disrupt the sensor.

Meanwhile, I hope this blog helped provide some clarity on Class A and Class B ports.

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.

5 Ways Flexible Manufacturing has Never Been Easier

Guest Contributor: Tom Rosenberg, Balluff

Flexible manufacturing has never been easier or more cost effective to implement, even down to lot-size-one, now that IO-Link has become an accepted standard. Fixed control and buried information is no longer acceptable. Driven by the needs of IIoT and Industry 4.0, IO-Link provides the additional data that unlocks the flexibility in modern automation equipment, and it’s here now!  As evidence, here are the top five examples of IO-Link enabled flexibility:

#5. Quick Change Tooling: The technology of inductive coupling connects standard IO-Link devices through an airgap. Change parts and End of Arm (EOA) tooling can quickly and reliably be changed and verified while maintaining connection with sensors and pneumatic valves. This is really cool technology…power through the air!

Image1

 

#4. On-the-fly Sensors Programming: Many sensor applications require new settings when the target changes, and the targets seem to always change. IO-Link enables this at minimal cost and very little time investment. It’s just built in.

Image 2

 

#3. Flexible Indicator Lights: Detailed communication with the operators no long requires a traditional HMI. In our flexible world, information such as variable process data, timing indication, machine status, run states and change over verification can be displayed at the point of use. This represents endless creativity possibilities.

Powertrain visualisieren

 

#2. Low cost RFID: Radio Frequency Identification (RFID) has been around for a while. But with the cost point of IO-Link, the applications have been rapidly climbing. From traditional manufacturing pallets to change-part tracking, the ease and cost effectiveness of RFID is at a record level. If you have ever thought about RFID, now is the time.

7_1_Produktionsdaten_Dokumentieren

 

#1. Move Away from Discrete to Continuously Variable Sensors: Moving from discrete, on-off sensors to continuously variable sensors (like analog but better) opens up tremendous flexibility. This eliminates multiple discrete sensors or re-positioning of sensors. One sensor can handle multiple types and sizes of products with no cost penalty. IO-Link makes this more economical than traditional analog with much more information available. This could be the best technology shift since the move to Ethernet based I/O networks.

8_1_induktiver_Abstand

So #1 was the move to Continuously Variable sensors using IO-Link. But the term, “Continuously Variable” doesn’t just roll off the tongue. We have discrete and analog sensors, but what should we call these sensors? Let me know your thoughts!

To learn more about RFID and IO-Link technology, 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.

Is IO-Link only for Simplifying Sensor Integration?

Guest contributor: Shishir Rege, Balluff

On several occasions, I was asked what other applications IO-Link is suitable for? Is it only for sensor integration? Well the answer is no! There are several uses for IO-Link and we are just beginning to scratch the surface for what IO-Link can do. In this blog post I will cover at least 7 common uses for IO-Link including sensor integration.
IO-Link in essence provides tremendous flexibility. Each available IO-Link port offers the possibility to connect devices from hundreds of manufacturers to build a resilient distributed modular controls architecture — that is essentially independent of the fieldbus or network. IO-Link is the first standardized sensor/actuator communication protocol as defined in IEC61131-9.

USE-CASE #1: Simplify sensor integration
Multitudes of IO-Link sensors from 100+ manufacturers can be connected using the simple 3-wire M12 prox cables. No shielded cables are required. Additionally, using IO-Link provides a parameterization feature and anti-tampering abilities- on the same 3 wires. The sensor can be configured remotely through a PLC or the controller and all the configuration settings can be stored for re-application when the sensor is replaced. This way, on your dreaded night shift changing complex sensor is just plug-n-play. Recipe changes on the line are a breeze too. For example, if you have an IO-Link color sensor configured to detect a green color and for the next batch you want to start detecting red color- with IO-Link it is simply a matter of sending a parameter for the color sensor – instead of sending a maintenance person to change the settings on the sensor itself — saving valuable time on the line.
color sensors

USE-CASE #2: Simplify analog sensor connections
In one of my previous blogs, “Simplify your existing analog sensor connection”, I detailed how connecting an analog sensor with single or multi-channel analog-to-IO-Link (A/D) converters can eliminate expensive shielded cables and expensive analog cards in the controller rack and avoids all the hassle that comes with the analog sensors.

USE-CASE #3: Simplify RFID communication
IO-Link makes applications with RFID particularly intriguing because it takes all the complexity of the RFID systems out for simple applications such as access control, error-proofing, number plate tracking and so on. In an open port on IO-Link master device you can add read/write or read only RFID heads and start programming. A couple of things to note here is this IO-Link based RFID is geared for small data communication where the data is about 100-200 bytes. Of-course if you are getting into high volume data applications a dedicated RFID is preferred. The applications mentioned above are not data intensive and IO-Link RFID is a perfect solution for it.

USE-CASE #4: Simplify Valve Integration
valve manifoldTypically valve banks from major manufacturers come with a D-sub connection with 25 pins. These 25 wires are now required to be routed back to the controls cabinet, cut, stripped, labeled, crimped and then terminated. The other expensive option is to use a network node on the valve bank itself, which requires routing expensive network cable and power cable to the valve bank. Not to mention the added cost for the network node on the valve bank. Several manufacturers now offer IO-Link on the valve manifold itself simplifying connection to 4-wires and utilizing inexpensive M12 prox cables. If you still have the old D-sub connector, an IO-Link to 25-pin D-sub connectors may be a better solution to simplify the valve bank installation. This way, you can easily retrofit your valve bank to get the enhanced diagnostics with IO-Link without much cost. Using IO-Link valve connectors not only saves time on integration by avoiding the labor associated with wire routing, but it also offers a cost effective solution compared to a network node on the valve manifold. Now you can get multiple valve manifolds on the single network node (used by the IO-Link master) rather than providing a single node for each valve manifold in use.

USE-CASE #5 Simplify Process Visualization
Who would have thought IO-Link can add intelligence to a stack light or status indicator? Well, we did. Balluff introduced an IO-Link based fully programmable LED tower light system to disrupt the status indicator market. The LED tower light, or SmartLight, uses a 3-wire M12 prox cable and offers different modes of operations such as standard stack light mode with up to 5 segments of various color lights to show the status of the system, or as a run-light mode to display particular information about your process such as system is running but soon needs a mechanical or electrical maintenance and this is done by simply changing colors of a running segment or the background segment. Another mode of operation could be a level mode where you can show the progress of process or show the fork-lift operators that the station is running low on parts. Since the Smartlight uses LEDs to show the information, the colors, and the intensity of the light can be programmed. If that is not enough you can also add a buzzer that offers programmable chopped, beep or continuous sound. The Smartlight takes all of the complexity of the stack light and adds more features and functions to upgrade your plant floor.

USE-CASE #6: Non-contact connection of power and data exchange
Several times on assembly lines, a question is how to provide power to the moving pallets to energize the sensors and I/O required for the operation? When multi-pin connectors are used the biggest problem is that the pins break by constantly connecting or disconnecting. Utilizing an inductive coupling device that can enable transfer of power and IO-Link data across an air-gap simplifies the installation and eliminates the unplanned down-time. With IO-Link inductive couplers, up to 32 bytes of data and power can be transferred. Yes you can activate valves over the inductive couplers!  More on inductive coupling can be found on my other series of blogs “Simple Concepts for Complex Automation”

USE-CASE #7: Build flexible high density I/O architectures.
IO PointsHow many I/O points are you hosting today on a single network drop? The typical answer is 16 I/O points. What happens when you need one additional I/O point or the end-user demands 20% additional I/O points on the machine? Until now, you were adding more network or fieldbus nodes and maintaining them. With I/O hubs powered by IO-link on that same M12 4-wire cable, now each network node can host up to 480 I/O points if you use 16 port IO-Link masters. Typically most of our customers use 8-port IO-Link masters and they have the capacity to build up to 240 configurable I/O on a single network drop. Each port on the I/O hub hosts two channels of I/O points with each channel configurable as input or output, as normally open or normally closed. Additionally, you can get diagnostics down to each port about over-current or short-circuit. And the good thing is, each I/O hub can be about 20m away.

In a nutshell, IO-Link can be used for more than just simplifying sensor integration and can help significantly reduce your costs for building flexible resilient controls architectures. Still don’t believe it? Contact us and we can work through your particular architecture to see if IO-Link offers a viable option for you on your next project.

cropped-cmafh-logo-with-tagline-caps1.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.

How do I make my analog sensor less complex?

Guest contributor: Shishir Rege, Balluff

So, you have a (or many) analog sensor in your application or system and they could be 4-20mA signal or 0-10V or even -10- +10V signal strength. You probably know that installing these specialty sensors takes some effort. You need shielded cables for signal transmission, the sensor probably has some digital interface for set-point settings or configuration. In all, there are probably 6-8 at minimum terminations for this single sensor. Furthermore, these expensive cables need to be routed properly to ensure minimal electromagnetic interference (EMI) on the wire. To make matter more complex, when its time to diagnose problem with the sensor, it is always on the back of your mind that may be the cable is catching some interference and giving improper readings or errors.

shieldedCablesOn the other hand, the cost side also is little tricky. You have the state of the art sensor that requires expensive shielded cable and the expensive analog input card (which generally has 4 channels- even if you use single channel), plus some digital I/O to get this single sensor to communicate to your PLC/PAC or controller. You are absolutely right, that is why people are demanding to have this sensor directly on their network so that it eliminates all the expensive cables and cards and talks directly to the controller on express way– so to speak.

Recently, there has been an explosion of industrial communication networks and fieldbuses. To name a few: EtherNet/IP, DeviceNet, PROFINET, PROFIBUS, CC-Link, CC-Link IE, Powerlink, Sercos, and the list goes on. As a machine builder, you want to be open to any network of customer’s choice. So, if that is the case, having network node on the sensor itself would make that sensor more bulky and expensive than before — but not only that, now the manufacturers have to develop sensor connectivity to ALL the networks and maintain separate inventory of each type. As a machine builder, it does put lot more stress on you as well to maintain different Bills of Materials (BOMs) for different projects – most likely – different sourcing channels and so on.

NetworksSo far what we discussed are two extremes; the way of the past with shielded cables and analog cards, and a wishful future where all devices are on the network. There is a middle ground that bridges yesterday’s method and the wishful future without adding any burden on manufacturers of the sensors or even the machine builders. The solution is IO-Link. IO-Link is the first standard (IEC 61131-9) sensor actuator communication technology. There are over 100+ members in the consortium that produce wide variety of sensors that can communicate over IO-Link.

If a sensor has IO-Link communication, denoted by  io-linklogo, then you can connect a standard M12 prox cable — let me stress– UNSHIELDED, to connect the sensor to the IO-Link port on the IO-Link master device. That’s it! No need to terminate connections, or buy expensive hardware. The IO-Link master device typically has 4, 8 or 16 ports to connect various IO-Link devices including I/O hubs, RFID, Valve connectors and more. (see picture below)

DistModIO

All signal communication and configuration now occurs on standard 3 conductor cable that you are currently using for your discrete sensors. The IO-Link master in turn acts as a gateway to the network. So, the IO-Link master sits on the network or fieldbus and collects all the sensors or discrete I/O information from devices and sends it to the controller or the PLC of the customer choice.

When your customer demands a different network or the fieldbus, the only thing that changes in your question is the master that talks to a different protocol.

In my next blog we will discuss how you can eliminate shielded cables and expensive analog cards for your existing analog sensor. Let me give you a hint– again the solution is with IO-Link.

cropped-cmafh-logo-with-tagline-caps1.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.

Solving Analog Integration Conundrum

Guest contributor: Shishir Rege, Balluff

These days, there are several options to solve the integration problems with analog sensors such as measurement or temperature sensors. This blog explains the several options for analog integration and the “expected” benefits.

Before we describe the options, let’s get a few things cleared up.  First, most controllers out there today do not understand analog at all: whenever a controller needs to record an analog value, an analog-to-digital converter is required.  On the other end of the equation is the actual sensor measuring the physical property, such as distance, temperature, pressure, inclination, etc.  This sensor, a transducer, converts the physical property into an analog signal.  These days with the advanced technologies and with the cost of microprocessors going down, it is hard to find a pure analog device.  This is because the piezo-electronics inside the sensor measures the true analog signal, but it is converted to a digital signal so that the microprocessor can synthesize it and convert it back to an analog signal.  You can read more about this in a previous blog of mine “How Do I Make My Analog Sensor Less Complex?”

Now let’s review the options available:

  1. The classical approach: an analog to digital converter card is installed inside the control cabinet next to the controller or a PLC. This card offers 2, 4, or even 8 channels of conversion from analog to digital so that the controller can process this information. The analog data can be a current measurement such as 0-20mA or 4-20mA, voltage measurement such as 0-10V, +5- -5V etc., or a temperature measurement such as PT100, PT1000, Type J, Type K and so on.  Prior to networks or IO-Link, this was the only option available, so people did not realize the down-side of this implementation.  The three major downsides are as follows:
  • Long sensor cable runs are required from the sensor all the way to the cabinet, and this required careful termination to ensure proper grounding and shielding.
  • There are no diagnostics available with this approach: it is always a brute-force method to determine whether the cable or the actual transducer/sensor has the issue. This causes longer down-times to troubleshoot problems and leads to a higher cost to maintain the architecture.
  • Every time a sensor needs to be replaced, the right tools have to be found (programming tools or a teaching sequence manual) to calibrate the new sensor before replacement. Again, this just added to the cost of downtime.
  1. The network approach — As networks or fieldbuses gained popularity, the network-based analog modules emerged. The long cable runs became short double-ended pre-wired connectors, significantly reducing the wiring cost. But this solution added the cost of network node and an additional power drop.  This approach did not solve the diagnostic problems (b) or the replacement problem above (c ). The cost of the network analog module was comparable to the analog card, so there was effectively no savings for end users in that area.  As the number of power drops increase, in most cases, the power supply becomes bigger or more power supplies are required for the application.
  2. The IO-Link sensor approach is a great approach to completely eliminate the analog hassle altogether. As I mentioned earlier, since the sensor already has a microprocessor that converts the signal to digital form for synthesis and signal stabilization, why not use that same digital data over a smarter communication to completely get rid of analog? In a nutshell, the data coming out of the sensor is no longer an analog value; instead it is a digital value of the actual result. So, now the controller can directly get the data in engineering units such as psi, bar, Celsius, Fahrenheit, meters, millimeters, and so on. NO MORE SCALING of data in the controller is necessary, there are no more worries of resolution, and best of all enhanced diagnostics are available with the sensor now. So, the sensor can alert the controller through IO-Link event data if it requires maintenance or if it is going out of commission soon.  With this approach, the analog conversion card is replaced by the IO-Link gateway module which comes in 4-channels or 8 channels.

Just to recap about the IO-Link sensor:

configurations
IndustrialNetwork
  1. IO-Link eliminated the analog cable hassle
  2. IO-Link eliminated the resolution and scaling issue
  3. IO-Link added enhanced diagnostics so that the end users can perform predictive maintenance instead of preventative maintenance.
  4. The IO-Link gateway modules offers configuration and parameter server functionality that allows storing the sensor configuration data either at the IO-Link master port or in the controller so that when it is a time to replace the sensor, all that is required is finding the sensor with the same part number and plugging it in the same port — and the job is done! No more calibration required. Of course, don’t forget to turn on this functionality on the IO-Link master port.

Well, this raises two questions:

  1. Where do I find IO-Link capable sensors? The answer is simple: the IO-Link consortium (www.IO-Link.com) has over 120 member companies that develop IO-Link devices. It is very likely that you will find the sensor in the IO-Link version. Want to use your existing sensor?  Balluff offers some innovative solutions that will allow you bring your analog sensor over to IO-Link.
  2. What is a cost adder for this approach? Well, IO-Link does a lot more than just eliminate your analog hassle. To find out more please visit my earlier blog “Is IO-Link only for Simplifying Sensor Integration?“

 

cropped-cmafh-logo-with-tagline-caps1.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.

Non-Contact Infrared Temperature Sensors with IO-Link – Enabler for Industry 4.0

Guest contributor: Manfred Munzl for Balluff

Automation in Steel-Plants

Modern production requires a very high level of automation. One big benefit of fully automated plants and processes is the reduction of faults and mishaps that may lead to highly expensive downtime. In large steel plants there are hundreds of red hot steel slabs moving around, being processed, milled and manufactured into various products such as wires, coils and bars. Keeping track of these objects is of utmost importance to ensure a smooth and cost efficient production. A blockage or damage of a production line usually leads to an unexpected downtime and it takes hours to be rectified and restart the process.

To meet the challenges of the manufacturing processes in modern steel plants you need to control and monitor automatically material flows. This applies especially the path of the workpieces through the plant (as components of the product to be manufactured) and will be placed also at locations with limited access or hazardous areas within the factory.

Detection of Hot Metal

Standard sensors such as inductive or photoelectric devices cannot be used near red hot objects as they either would be damaged by the heat or would be overloaded with the tremendous infrared radiation emitted by the object. However, there is a sensing principle that uses this infrared radiation to detect the hot object and even gives a clue about its temperature.

Non-contact infrared thermometers meet the requirements and are successfully used in this kind of application. They can be mounted away from the hot object so they are not destroyed by the heat, yet they capture the Infrared emitted as this radiation travels virtually unlimited. Moreover, the wavelength and intensity of the radiation can be evaluated to allow for a pretty accurate temperature reading of the object. Still there are certain parameters to be set or taught to make the device work correctly. As many of these infrared thermometers are placed in hazardous or inaccessible places, a parametrization or adjustment directly at the device is often difficult or even impossible. Therefore, an intelligent interface is required both to monitor and read out data generated by the sensor and – even more important – to download parameters and other data to the sensor.

Technical basics of Infrared Hot-Metal-Detectors

Traditional photoelectric sensors generate a signal and receive in most cases a reflection of this signal. Contrary to this, an infrared sensor does not emit any signal. The physical basics of an infrared sensor is to detect infrared radiation which is emitted by any object.
Each body, with a temperature above absolute zero (-273.15°C or −459.67 °F) emits an
electromagnetic radiation from its surface, which is proportional to its intrinsic
temperature. This radiation is called temperature or heat radiation.

By use of different technologies, such as photodiodes or thermopiles, this radiation can be detected and measured over a long distance.

Key Advantages of Infrared Thermometry

This non-contact, optical-based measuring method offers various advantages over thermometers with direct contact:

  • Reactionless measurement, i.e. the measured object remains unaffected, making it possible to measure the temperature of very small parts
  • Very fast measuring frequence
  • Measurement over long distances is possible, measuring device can be located outside the hazardous area
  • Very hot temperatures can be measured
  • Object detection of very hot parts: pyrometers can be used for object detection of very hot parts where conventional optical sensors are limited by the high infrared radiation
  • Measurement of moving objects is possible
  • No wear at the measuring point
  • Non-hazardous measurement of electrically live parts

IO-Link for smarter sensors

IO-Link as sensor interface has been established for nearly all sensor types in the past 10 years. It is a standardized uniform interface for sensors and actuators irrespective of their complexity. They provide consistent communication between devices and the control system/HMI.  It also allows for a dynamic change of sensor parameters by the controller or the operator on the HMI thus reducing downtimes for product changeovers. If a device needs to be replaced there is automatic parameter reassignment as soon as the new device has been installed and connected. This too reduces manual intervention and prevents incorrect settings. No special device-proprietary software is needed and wiring is easy, using three wire standard cables without any need for shielding.

Therefore, IO-Link is the ideal interface for a non-contact temperature sensor.

All values and data generated within the temperature sensor can be uploaded to the control system and can be used for condition monitoring and preventive maintenance purposes. As steel plants need to know in-process data to maintain a constant high quality of their products, sensors that provide more data than just a binary signal will generate extra benefit for a reliable, smooth production in the Industry 4.0 realm.

To learn more about this technology 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.