Industrial operators must embrace under-utilised IO-Link technology to enhance visibility of asset health, according to Milesh Patel, a Supplier Manager, Automation & Control, for RS UK & Ireland.

In any industrial environment, having a real-time accurate picture of asset health to keep operations moving and minimise downtime is a necessity, not a luxury. Sensors have long been used to help engineers identify potential issues, and the launch of IO-Link more than a decade ago greatly enhanced the capabilities and functionality of sensor technology by unlocking previously inaccessible sensor status information. This helps operators reduce maintenance costs and increase equipment uptime.

In the 15 years since its launch, IO-Link has duly progressed and become a standard sensor feature, but whether it is being adequately utilised by OEMs and machine builders is questionable: some may argue it isn’t being optimised in the field. IO-Link technology holds many benefits, but there are perceived barriers to this technology becoming truly mature.

The benefits of IO-Link 

IO-Link enables fast maintenance: the last metre between the field level of automation and the sensor/actuator level becomes capable of communication. This enhances the ‘normal’ capabilities of sensors from being able to simply highlight process variables, to making identification information, parameters and status of the device available. The capability to take information from sensors, self-diagnose and convey it back to the control system facilitates higher levels of predictive over preventative maintenance, increasing uptime.

The real beauty of the technology lies in the ability to utilise existing wiring. It transmits information via the sensor or actuator’s three-wire connection, making it invisible to the system and, therefore, not affecting basic sensor operations in any way. Diagnostics information can be sent over the same line as the process data. Other benefits include reduced documentation or expert knowledge requirements thanks to the fact that device parameters are stored in the host automation system and can be automatically downloaded.

The growth of IO-Link

The IO-Link protocol was launched in 2009, followed by the publication of the IEC 61131-9, Single-drop digital communication interface (SDCI) for small sensors and actuators standard in 2013. The technology standard is managed by the industry association Profibus and Profinet International.

Since the 2009 launch, the number of member companies committing to the standard has grown from 41 to more than 400 in 2024.

It is estimated that during 2024 there will be over 40 million active IO-Link nodes in the field. This illustrates the technology’s growth from being a niche addition to high end sensors from sensing technology pioneers, to becoming a standard feature on many sensors and actuators, supported by a host of gateways and networking devices.

Breaking down the barriers 

Choice may once have been considered a barrier to IO-Link adoption, but the range of IO-Link enabled sensors and actuators is bigger than ever, with virtually every global automation brand now a member of the community and adding IO-Link options into their offering. And while the cost could be another perceived barrier – around five years ago, there was a significant premium for IO-Link capability – this situation has evolved with lower cost and entry-level sensors coming to market offering the technology. Distributors are also starting to offer their own-brand IO-Link enabled sensors: RS offers them within the RS PRO offer.

The issue of complexity has also put many off implementing IO-Link, but the tools, interface hardware and software extensions to install IO-Link are now commonplace. It’s easier than ever to implement into existing PLC or control system code, allowing existing designs to be simply upgraded to benefit from IO-Link.

Given these perceived barriers, it’s understandable that adoption of IO-Link isn’t as prolific as it should be. But it’s high time these barriers were broken down, to enable all operators to reap the rewards of embracing this technology. With the gold standard of efficiency in industrial operations being based firmly on a robust predictive maintenance strategy, those who ignore the full capabilities of IO-Link should do so at their peril.

uk.rs-online.com