Mix simple field devices and complex Ethernet/fieldbus-enabled products across a control system

Zin May Thant is global marketing manager, distributed I/O portfolio, and Todd Bissell is strategic marketing manager, sensing, safety and industrial control portfolio, at Rockwell Automation.

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What are the advantages of IO-Link in terms of diagnostics?

Zin May Thant, global marketing manager, distributed I/O portfolio, Rockwell Automation: Leveraging IO-Link technology allows utilization of a plant or machine’s greatest asset—real-time data—to improve throughput and overall equipment effectiveness (OEE).

With more capacity than standard digital or analog signals, IO-Link offers more advanced diagnostics data beyond basic process data to help monitor the status and health of the IO-Link-enabled devices. The kind of diagnostics data that can be retrieved depends on the device manufacturer. This data could include diagnostics event-logging that allows users to perform predictive maintenance while enabling them to identify the issue and troubleshoot faster, reducing downtime. The IO-Link signal quality could also be monitored, which helps determine the validity of the values read.

How does IO-Link handle multi-sensor devices? Can I configure and access data from individual sensors within a single IO-Link device?

Todd Bissell, strategic marketing manager, sensing, safety and industrial control portfolio, Rockwell Automation: If you have a multi-sensor IO-Link-enabled device, you should be able to configure and access data from the individual sensors. This is possible due to the device profile that would define how data from the various sensors are structured for transmission. Users can refer to the I/O device description (IODD) file of the multi-sensor device to determine how to read and write data for individual sensors.

What cable topology options are available with IO-Link? Can I use daisy-chain connections, or is a dedicated point-to-point connection required for each device?

Zin May Thant, global marketing manager, distributed I/O portfolio, Rockwell Automation: IO-Link is a point-to-point communication protocol, so each IO-Link device has a dedicated connection to the port of an IO-Link master block. Daisy-chaining is not possible using IO-Link.

How does IO-Link integrate with different fieldbus protocols commonly used in automation systems?

Todd Bissell, strategic marketing manager, sensing, safety and industrial control portfolio, Rockwell Automation: IO-Link is fieldbus-independent and can integrate with different fieldbus protocols via the IO-Link master. The IO-Link master, being the gateway between IO-Link enabled devices and the controller, will be the device that is connected to the controller via the corresponding fieldbus protocols of the control system, for example, EtherNet/IP. When the main network is EtherNet/IP, IO-Link is geared toward providing an Ethernet-like performance and user experience for field devices where direct Ethernet connection is too costly or bulky. IO-Link allows the connection of simpler field devices and more complex Ethernet/fieldbus-enabled products to be mixed seamlessly across a control system.

What are the cost implications of implementing IO-Link compared to traditional wiring methods? Is the upfront cost of IO-Link devices offset by long-term benefits like reduced wiring complexity and improved diagnostics?

Zin May Thant, global marketing manager, distributed I/O portfolio, Rockwell Automation: Implementing IO-Link requires procuring not just IO-Link-enabled devices but also IO-Link masters and peripherals such as cables. The technology and product training for your workforce also require some additional upfront investment.

Despite the upfront costs, IO-Link is a worthwhile investment that can be offset by long-term benefits such as reduced wiring complexity and improved diagnostics. While avoiding a costly and unplanned downtime situation alone, with the diagnostics data available, can justify the investment in an IO-Link solution, there are many other benefits. Another plus point for IO-Link is the ease of configuration and replacement, which allows flexibility in making multiple device parameter changes based on application requirements and switching out devices without the need for manual reconfiguration. This will help alleviate any concerns about the lack of trained personnel on-site if there is a device failure.

Tell us about one of your organization’s state-of-the-art IO-Link offerings.

Todd Bissell, strategic marketing manager, sensing, safety and industrial control portfolio, Rockwell Automation: Rockwell Automation is constantly expanding its line of smart, IO-Link enabled products, which include sensors, masters, hubs, tower lights and electronic circuit protection.

The ArmorBlock 5000 IO-Link master blocks are the latest IO-Link master offerings from Rockwell Automation. The product was released in the first half of 2023 and is available in three power variants for various industry and application needs. The IO-Link master block comes with IO-Link Class A and Class B ports, expanding the variety of potential IO-Link-enabled devices that users can use. Its highly integrated IO-Link capability provides an improved experience of integrating IO-Link enabled devices with Allen-Bradley controllers. The block also supports digital inputs and outputs, enabling a highly flexible and configurable solution to achieve the users’ desired business outcomes.

Anything else that you'd like to add about IO-Link?

Zin May Thant, global marketing manager, distributed I/O portfolio, Rockwell Automation: To build smart machines that drive efficiency and competitiveness, you need more actionable, useful data. Accessing this data will be easier with IO-Link technology. Being fieldbus-agnostic, there are also fewer barriers in implementing IO-Link. According to several industry reports, it is projected that IO-Link will see exponential growth over the next 10 years at double digits compound annual growth rate (CAGR), driven by the need for simplification, increased flexibility and scalability in manufacturing.