Intro to IO-Link

An introduction to IO-Link. Gives an overview of how to add IO-Link to existing & new automation systems. By Neil Farrow, P.E. This is based on a presentation to ISA (the International Society for Automation).

1. IEC 61131-9
Neil Farrow, P.E.
A standardized IO technology for communication
with sensors and actuators.

2. •Universal –Open Standard (IEC 61131-9)
•Smart –Digital communications to and from sensors (a nd actuators).
•Easy –Standard configuration format & methods.
from www.IO-Link.com

3. Agenda Agenda Agenda Agenda
• Introduction of IO-Link
• Details on IO-Link Masters and Sensors
• Configuration
• Top 10 list
• The future is Now!
• Live Demonstration

4. Where did it come from? Where did it come from? Where did it come from? Where did it come from?
Key stakeholders defined the specifications
• PLC
• Sensor
• Software
• IC

5. Some Key Benefits
• Uses Twist-on connectors instead of wire termination s.
• More Diagnostics.
• Change setpoints from PLC.
• Compatible with existing sensors.

6. Terms & Definitions Terms & Definitions Terms & Definitions Terms & Definitions
•COM . . . . .Communications Operating Mode (COM1/CO M2/COM3)
•OLE’ . . . . . Object Linking & Embedding (Active-X )
•OPC . . . . . OLE for Process Control
•OPC-UA . . OPC-Unified Architecture
•HiFi . . . . . .High Fidelity (Audio)
•Wi-Fi. . . . . Made-up marketing term for Wireless Ethernet
•IOT. . . . . . Internet Of Things (Internet access + Wi-Fi)
•IIOT . . . . . .Industrial IOT

7. Terms & Definitions Terms & Definitions Terms & Definitions Terms & Definitions
•XML. . . . . eXtensibleMark-up Language
(Extensible means extendable; Able to accommodate change)
•IODD . . . . . IO-link Device Description file (Lik e an EDS file)
•MQTT . . . . MQTelemetry Transport. An open & compac t protocol.
•SDCI. . . . . Single Drop Communications Interface (IO-Link)
•TSN. . . . . . .Time Sensitive Network
•IT/OT . . . . .Information Technology / Operational Technology

8. IEC -The International Electrotechnical Commission (I EC)
prepares and publishes International Standards for all
electrical, and electronic, and related technologie s.
Standards Standards Standards Standards
IEC 61131-9

9. IEC 61131 IEC 61131 IEC 61131 IEC 61131 ––––Standard for Programmable Controllers Standard for Programmable Controllers Standard for Programmable Controllers Standard for Programmable Controllers
61131-3 –PLC Languages.
• Ladder • Function Block • Statement List
• Structured Text • Sequential Function Charts
61131-9 -Single-drop digital communication interfac e
for small sensors and actuators (SDCI).
• This is marketed as IO-Link.

10. 5,300,000+ nodes in 2017
from www.IO-Link.com

11. www.io www.io www.io www.io----link.com link.com link.com link.com
from www.IO-Link.com

12. Some IO-Link Member companies
from www.IO-Link.com

13. An IO An IO An IO An IO----Link System Link System Link System Link System

14. Components of An IO Components of An IO Components of An IO Components of An IO----Link System Link System Link System Link System

15. IOIOIO IO----Link Compatibility Matrix Link Compatibility Matrix Link Compatibility Matrix Link Compatibility Matrix
User’s Fear:
IO-Link Masters
IO-Link Sensors

16. Any PLC* Any Any PLC* Any Any PLC* Any Any PLC* Any Sensor Sensor Sensor Sensor** Any Master ** Any Master ** Any Master ** Any Master
No Compatibility Matrix No Compatibility Matrix No Compatibility Matrix No Compatibility Matrix
The Reality: The Reality: The Reality: The Reality:

17. IOIOIO IO----Link Compatibility Matrix Link Compatibility Matrix Link Compatibility Matrix Link Compatibility Matrix
•Use Any PLC*
* With a fieldbus
PLC Reality:

18. •Use
Existing 24VDC sensors**.
•Use IO-Link sensors from any vendor.
•Use existing M12, M8, or M5 cables***.
*** 20 meters or shorter cables. Unshielded.
**Discrete PNP
[4-20mA is not in the specification.]
NPN is not in the specification.
Sensor Reality Sensor Reality Sensor Reality Sensor Reality::::

19. Sensor Reality: Sensor Reality: Sensor Reality: Sensor Reality:
IO-Link Masters recognize both
IO-Link sensors and
24VDC sensors.
IO-Link Master M12:
Remote I/O M12:

20. Wiring: Wiring: Wiring: Wiring:
Connectors are the same M12/M8/M5 as always.
Traditional Sensor:IO-Link Sensor:
Images from www.balluff.com

21. Next: Machine Wiring Evolution Next: Machine Wiring Evolution Next: Machine Wiring Evolution Next: Machine Wiring Evolution
Image from http://mindgasms.theblogpress.com
Image By Simon Muckenhirn / Violette Koppe

22. Traditional Machine Wiring Traditional Machine Wiring Traditional Machine Wiring Traditional Machine Wiring
Image from www.balluff.com

23. Traditional Machine Wiring Traditional Machine Wiring Traditional Machine Wiring Traditional Machine Wiring

24. Wiring Blocks Wiring Blocks Wiring Blocks Wiring Blocks

25. Fieldbus & Remote I/O Blocks Fieldbus & Remote I/O Blocks Fieldbus & Remote I/O Blocks Fieldbus & Remote I/O Blocks

26. IOIOIO IO----Link Master Link Master Link Master Link Master
Digital
Data
Digital
Data
Digital
Data
Digital
Data
Digital
Data
“Go the last few meters”

27. $?$?$? Remote I/O $?$?$? Remote I/O $?$?$? Remote I/O $?$?$? Remote I/O IIIIIOIOIO IO----Link Master Link Master Link Master Link Master
Extra Cost -List
Up to $50 for master*
Up to $0.50 for each sensor
Extra Cost -Street Close to $0 for master*
$0 for each sensor
* Over Remote wiring block w/ fieldbus

28. Traditional Wiring Traditional Wiring Traditional Wiring Traditional Wiring IIIIIOIOIO IO----Link Master Link Master Link Master Link Master
40x
~ 5x $500
analog card
~ $40 x40 cable
20 m shielded
~ ~ ~ ~ $41,00 total $41,00 total $41,00 total $41,00 total
800 m cable 800 m cable 800 m cable 800 m cable
(2,625 ft) (2,625 ft) (2,625 ft) (2,625 ft)
Slide By Simon Muckenhirn / Violette Koppe
5x
~ 5x $450 Master
~ 4x $30 Ethernet
cables (Daisy chain)
~ 40 x $14 cables 2m
~ 1x $85
Ethernet cable
~ ~ ~ ~ $3,015 total $3,015 total $3,015 total $3,015 total
100 m cable 100 m cable 100 m cable 100 m cable
Distance Sensors

29. What is IO What is IO What is IO What is IO----Link? An overview. Link? An overview. Link? An overview. Link? An overview.
•Ethernet based point-to-point protocol.
•From Master to each Sensor.
•Communication is both ways.
•Get extra diagnostic information from the sensor.
•Send new setpoints to the sensor.
•Sensor Configuration is stored in the Master.
•Hot-swap sensors & the setpoints get re-loaded into the new
sensor.
•Update setpoints for product changeover or remote t each.

30. Typical Typical Typical Typical
Control Control Control Control
System System System System

31. Next, more details . . . Next, more details . . . Next, more details . . . Next, more details . . .
IO-Link Masters
IO-Link Sensors

32. IOIOIO IO----Link Masters Link Masters Link Masters Link Masters
M5 M8 M12
Connections:
• Sensor Inputs
• Ethernet In & Out
• Power In & Out

33. IOIOIO IO----Link Masters Link Masters Link Masters Link Masters
Fieldbus in/out
24VDC Power in/out
4 IO-Link Sensor & Actuator Connections
4 traditional sensor connections

34. IOIOIO IO----Link Masters Link Masters Link Masters Link Masters
To Next
IO-Link Master

35. IOIOIO IO----Link Masters Link Masters Link Masters Link Masters
Check that Sub-masters can have IO-Link Sensors.

36. IOIOIO IO----Link Link Link Link Masters Masters Masters Masters ––––To update existing machines To update existing machines To update existing machines To update existing machines
Point IO
1734-IOL
Point IO-Link Master
Add one IO-Link Sensor
DIN Rail Mount
Add IO-Link to existing Junction box
Or control panel.
Many Masters are IP67. When you need
IP69k, You need an IP69k enclosure.
Base model Compact Logix can only have 4 network de vices.

37. Next: Sensor Evolution Next: Sensor Evolution Next: Sensor Evolution Next: Sensor Evolution
Image from http://mindgasms.theblogpress.com
Images from www.SensoPart.com

38. Typical Discrete Sensor Typical Discrete Sensor Typical Discrete Sensor Typical Discrete Sensor - ---199019901990 1990

39. Typical Sensor Typical Sensor Typical Sensor Typical Sensor – –––212121 21
stststst
Century Century Century Century
8-pin
16-pin 5-pin

40. Typical Prox Typical Prox Typical Prox Typical Prox – –––212121 21
stststst
Century Century Century Century
•Multiple Discrete Outputs.
•Weak signal.
•Multiple Setpoints.
•Multiple Discrete Inputs.
•Remote teach.
•Multiple configurations.
•On / Off.

41. Analog Signals Analog Signals Analog Signals Analog Signals
•4-20mA or 0-10 VDC.
•12 bit A/D converters.
•Best Resolution = 2^12 = 4096
•Sensor Example
•Range of 70 meters
•Resolution of 2 millimeters.
•70 / (2/1000) = 35,000 increments.
•With an A/D it’s only 4096 ( 8 x )
Resolution is lost just
by using an analog input
Configure Double-Integer register
In the PLC to be updated repeatedly.
Resolution is preserved

42. Analog Signals Analog Signals Analog Signals Analog Signals
Open Port
Open? Fault?
Ack? Time-
out?
Parse Data
Data
Valid?
Data
ok?
Reset
Get Data
Request Data
Done
For PLC Serial communication, Just
write a ladder program like Program this.
Configure
Data Updates

43. Analog Signals Analog Signals Analog Signals Analog Signals
No Analog Input Modules
Send digital values to PLC register
through IO-Link Master

44. End of History lesson End of History lesson End of History lesson End of History lesson
Back to

45. IODD File IODD File IODD File IODD File
•IODD = Input / Output Device Description.
Like EDS or GSD
•XML Format.
•The IO-Link master has to have a copy of the IODD f ile for each
unique sensor connected to it.
zipzip zipzip
IODD
Slide By Simon Muckenhirn

46. IODD is in XML format IODD is in XML format IODD is in XML format IODD is in XML format

47. IODD files IODD files IODD files IODD files
Data Table (FT 55 Data Table (FT 55 Data Table (FT 55 Data Table (FT 55- ---CM CM CM CM ----Color Senosr) Color Senosr) Color Senosr) Color Senosr)

48. IODD files IODD files IODD files IODD files
Data Table (FT 55 Data Table (FT 55 Data Table (FT 55 Data Table (FT 55- ---RLAP TOF) RLAP TOF) RLAP TOF) RLAP TOF) 01.09.2017
Simon Muckenhirn
CCCCyclic yclic yclic yclicdata datadata data/ / / / process process process processdata datadata data Distance Distance Distance Distance
Status Q1 / Q2 Status Q1 / Q2 Status Q1 / Q2 Status Q1 / Q2
Signal Signal Signal Signal quality quality quality quality
Acyclic data Acyclic data Acyclic data Acyclic data Identification and description of Identification and description of Identification and description of Identification and description of
product. product. product. product.
Operating time Operating time Operating time Operating time
Commands & events Commands & events Commands & events Commands & events Switchpoint Switchpoint Switchpoint Switchpointsensor sensor sensor sensor
Switch mode sensor Switch mode sensor Switch mode sensor Switch mode sensor

49. Types of data Types of data Types of data Types of data
•Process data
•Service data
•Events

50. Types of data & speeds Types of data & speeds Types of data & speeds Types of data & speeds
•Process data -Sent Cyclically (every communication cycle) Examples are Distance Measured, and Part Present.
About every 2.3 ms. Can contain between 1 bit and 32 bytes of information. •Service data -Service protocol data units (SPDUs) allow the user to
retrieve detailed information about the device. Up to 16,000 blocks. ~400ms.
Examples include configuration data (e.g. activatio n, deactivation of functions).
And Sensor manufacturer no. & model no. •Events -Events are reported without waiting for an SPDU to be queried. Examples include diagnostics. • COM1 -4,800 baud • COM2 -38,400 baud • COM3 230,400 baud

51. Finding an IODD file Finding an IODD file Finding an IODD file Finding an IODD file
Two ways:
•Senor manufacturer’s web
site.
I.E.
www.SensoPart.com
•IODD Finder. www.ioddfinder.io-link.com

52. Load IODD file to IO Load IODD file to IO Load IODD file to IO Load IODD file to IO- ---Link Master Link Master Link Master Link Master
Two typical ways:
•Use software provided
by the manufacturer.
•Use the IO-link
Master’s web server.
•Some PLC
programming software
also.

53. Top 10 reasons to use IO Top 10 reasons to use IO Top 10 reasons to use IO Top 10 reasons to use IO- ---Link LinkLink Link
1. More accurate data (not limited by 12-bit A/D 40 95)
2. Help reduce downtime -out of the box.
a. Hot-swap sensors w/ no re-configuration
b. LED's on master.
c. Track down problem down to the sensor from IO-Li nk Master's web browser.
3. Help reduce downtime even more -requires extra c onfiguration & programming.
b. Error messaging from the exact problem sensor.
c. Low received signal strength warnings.
d. Operating time much shorter than the PLC, or oth er blocks of sensors.
e. Remote teach HMI maintenance screens for quick & Easy commisioning.
4. Reduce Spare Parts Inventory.
a. Configurable sensors can take the place of multi ple fixed sensors.
b. Replace spare sensors with IO-Link sensors. IO- Link sensors work on
existing Discrete and Analog Input modules & on IO- Link masters.

54. Top 10 reasons to use IO Top 10 reasons to use IO Top 10 reasons to use IO Top 10 reasons to use IO- ---Link LinkLink Link
5. Quick product changeover.
a. Change sensor configuration on-the-fly from the PLC (change sensor trip
points when you change products).
6. More data from the sensor (Received signal stren gth, Temperature, diagnostics.)
7. All sensors are similar. If you can configure o ne, you can configure them all.
8. Use your favorite devices. Add IO-Link where it helps.
Any PLC (with a fieldbus). Any Sensor. Any IO-Lin k master.
9. Fewer wiring connections.
Saves labor. Saves troubleshooting. Shorter start up.
10. Save data directly from sensor to database (Wi thout PLC programming)
a. Predictive maintenance.
b. Warnings & Alarms.
c. Historical trends.

55. The Future began yesterday The Future began yesterday The Future began yesterday The Future began yesterday
Image from www.centerforhealthythinking.com

56. Tie it all together Tie it all together Tie it all together Tie it all together

57. Tie it all together Tie it all together Tie it all together Tie it all together

58. IIOT, Big Data, MES, “The Cloud” IIOT, Big Data, MES, “The Cloud” IIOT, Big Data, MES, “The Cloud” IIOT, Big Data, MES, “The Cloud”

59. Tie it all together Tie it all together Tie it all together Tie it all together
•IIOT = OPC-UA + IO-Link
•Big Data = Save lots of data to a DB. Then analyze it.
•SPC
•Predictive Maintenance
•Standards for adding OPC-UA into the IO-Link
standards are coming.
•You can get an IO-Link master with OPC-UA today.

60. Load IODD file Load IODD file Load IODD file Load IODD file – –––Live Demo Live Demo Live Demo Live Demo •MenuBar: Attached Devices
•Upload File
•Choose File
•Upload
•MenuBar: Configuration
•Port 1 -Edit
•Clear
•Get Attached
•Save
•MenuBar: Attached Devices
•Port 1

61. SensoVisualize SensoVisualize SensoVisualize SensoVisualize - ---RealRealReal Real----Time trend of color sensor Time trend of color sensor Time trend of color sensor Time trend of color sensor
•Capture RTTdata.
•Teach Sensor.
•SesorIcon / Parameter / Parameter.
•Parameter / Configure Sensor / Configure teach outp uts
•Teach
•Single Value Teach / Teach Apply

62. Resources Resources Resources Resources
•
http://www.io-link.com/share/Downloads/At-a-glance/ IO- Link_System_Description_engl_2013.pdf
•
https://en.wikipedia.org/wiki/IEC_61131
•
https://en.wikipedia.org/wiki/Industry_4.0
•
https://en.wikipedia.org/wiki/XML
•
http://www.iiconsortium.org/
•
https://opcfoundation.org/
•
http://avnu.org/
•
www.SensoPart.com
•
www.io-link.com
Neil Farrow, P.E.
www.SensoPart.com
“If you don’t [Use IO-Link] this
year, you’ll be one year older
when you do.” –Warren Miller