IO-Link unlocking: what it is and why it matters for modern automation

Over the last few years, the use of IO-Link as a communication protocol in industrial plants has developed significantly.

By the end of 2023, the total number of installed IO-Link nodes had reached 51.6 million, according to the annual survey of newly installed nodes conducted by the industry trade group PROFIBUS & PROFINET International (PI). Last year, 15.9 million IO-Link devices were installed, a record increase of 89% compared to 8.4 million devices installed in 2022.

The increase should come as no surprise to any plant already using IO-Link to expand access to plant and equipment data at the lowest level in the field, including configuration, identification and diagnostic data.

What exactly is IO-Link?

IO-Link is the first globally standardized input/output technology designed to communicate with sensors and actuators and to connect to an automation system.

Unlike field bus, it is not a proprietary communication protocol, but a recognized international standard (IEC 61131-9) that ensures compatibility and interoperability between devices from different manufacturers.

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As described in the IEC 61131-9 standard, IO-Link is a point-to-point communications protocol, which means it connects two devices directly. This makes it simple to implement because it uses the same cables and connectors that engineers are already familiar with.

IO-Link provides bidirectional communication. In other words, data flows back and forth between the control system and field devices. The configuration provides real-time process data and diagnostic information from sensors and actuators, enabling more precise control and faster troubleshooting.

Essentially, an IO-Link device—such as a smart sensor, actuator, or mechatronic component—takes existing connection technology and elevates it by adding intelligent communication capabilities that make automation systems more efficient and responsive. IO-Link is advertised as being as easy to use as a traditional 3-wire setup, only more efficient and versatile. A typical IO-Link system consists of an IO-Link master, IO-Link devices, and cables connecting the IO-Link devices to the IO-Link master ports.

Why is IO-Link important?

A common misconception about IO-Link is that it can replace EtherNet/IP or Profinet. Rather, it is a complementary networking technology that can provide better overall performance and reliability.

IO-Link is designed as a simple, universal or open standard and aims to simplify the connectivity of smart sensors and smart devices on the factory floor. No special wiring or connectors are needed. Requires only standard M12/M8/M5 cables.

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A useful analogyas described wa blog specialist in sensors and automation Balluff website, is to think of IO-Link as USB for industrial automation. This makeup is useful IN offering IO–Cufflinks rolesto me IN enabling one of the most important operational ones objectiveS: to provide equipment availability.

Five factors that make IO-Link essential in machine design

Communicate with equipment at the lowest level. IO-Link provides bidirectional communication between sensors and actuators and low-level control systems. Smart IO-Link devices can provide data on temperature, load levels, error codes, configuration and parameter issues.

Replace analog signals with digital signals that enable real-time monitoring. IO-Link communication provides detailed diagnostic information based on raw sensor values, thus enabling predictive maintenance and faster troubleshooting. This results in increased operating time, reliability and equipment lifespan.

Increase compatibility with standard equipment. IO-Link uses standard unshielded 3-wire cables, which simplifies wiring and reduces installation costs. Because there is no need for special cables, connectors or complex field bus networks, installation can be cost-effective and easier to implement.

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Ensure better device management and better data quality. Devices can be configured remotely, which streamlines configuration and adjustment processes.

They offer a high degree of scalability and flexibility. Businesses of all sizes can benefit because IO-Link enables a modular approach to system design and supports scalability. New sensors or actuators can be added to the system without significant changes to the overall architecture, providing flexibility for future expansions.

Helping manufacturers create future-proof processes

Designed with future technological advancements in mind, IO-Link offers advanced communication capabilities along with ease of integration, improved diagnostics and remote management capabilities. With standardized interfaces, more data can be collected and shared to optimize industrial processes.