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IO-Link

Enabling the Connected Enterprise


Craig Brockman
Marketing Manager Sensing and Connectivity
08/10/16

PUBLIC

Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 1


Agenda

Introduction to IO-Link

Benefits of IO-Link

RA IO-Link Portfolio

Use Cases

NEW

PUBLIC Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 2


What is IO-Link?
IO-Link is a worldwide open-standard protocol (IEC 61131-9) that allows sensors to easily
integrate into a control system
IO-Link is NOT a fieldbus but an enhanced development of the current connection
technology for sensors and actuators
Point to Point communications between sensor and IO Block

Forward / Backward compatible with standard sensors

IO-Link uses the same cables as standard sensors

An IOLink system consists of IOLink devices sensors, actuators or combinations


thereof a standard 3wire cable and an IOLink Master
Allows sensing devices to be visible on EtherNet/IP
Access to I/O data and configuration data

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What is IO-Link?
IO-Link sensors act the same as the standard I/O sensors until connected to an IO-Link master
No new part numbers
One part number to stock
When connected consistent communication between sensors and the controller is established (Access
to all process data, diagnostic data, and sensor parameters)
Process Data is any information (up to 32 bytes) the sensor sends to the IO-Link master each
communication cycle (ie: sensor status, margin status, temp, counter or timer values, etc.)
Varies from sensor to sensor
Up to 32 bytes of data compared to 1 bit today
Consistent diagnostic information reduces troubleshooting efforts and supports preventative
maintenance (limited diagnostics today displayed thru LEDs)
Sensor parameters can be accessed for initial setup or dynamically for increased productivity
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IO-Link: An Enabling Technology for The
Connected Enterprise
The Connected Enterprise facilitates the Connected Enterprise
convergence of information technology and
operations and the real-time information flow
Integrated Architecture
between them
The Connected Enterprise allows us to create A-B Controller
a smarter, more productive and more secure
environment
A-B IO-Link Masters
Our smart sensors are the input devices for
The Connected Enterprise A-B IO-Link Sensors
42J 42E 45CR 871T
T F M M

Smart Sensors. Smart Machines. Smart Manufacturing.


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How are Field I/O Signals Handled Today?

EtherNet I/P

Measurement Sensor
Photo Sensor/Color Sensor Actuator/Valve Manifold (Analog Input)
(Digital Input) (Digital Output)
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How Does it Change with IO-Link?

EtherNet I/P EtherNet I/P

1734-4IOL 1732E-8IOLM12R

Photo Sensor
Photo Sensor
Measurement Color Sensor
Sensor

Inductive
Inductive Proximity
Actuator / Valve Proximity
Actuator / Valve
Manifold Manifold Measurement
Color Sensor
Sensor

In-Cabinet Solution On-Machine Solution

PUBLIC Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 9


Agenda

Introduction to IO-Link

Benefits of IO-Link

RA IO-Link Portfolio

Use Cases

NEW

PUBLIC Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 10


What is the Benefit of IO-Link?
Premier Integration

Premier Integration: When using the full Rockwell Automation solution, customers are
afforded a enhanced level of integration plus features and functionality not available with
competitive offerings:
Studio 5000 Logix Designer, a single programming environment that provides access to IO data and
configuration parameters across the entire Integrated Architecture system
Add-on-Profile (AOP) that simplifies the setup of Allen-Bradley IO-Link devices by organizing sensor
information and configurable parameters for intuitive programming

Automatic Device Configuration (ADC): Sensor configurations can be stored in the Logix controller and
downloaded to new/replacement sensors without the need for re-teaching/re-programming

Tag Names and structure for IO-Link process data are automatically generated from the sensor IO Device
Description (IODD) files (contextualized data)

RA offers IO-Link Sensors, IO-Link Master, and Controllers


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What is the Benefit of IO-Link?
Automatic Device Configuration (ADC)
ADC: Sensor configurations can be stored in the IO-Link
EtherNet I/P master and Logix controller and downloaded to
new/replacement sensors (of the same catalog number)
without the need for re-teaching/re-programming
1732E-8IOLM12R
Building multiple machines (simple project download)
Easy sensor replacement
42JT
Photoelectric 45CRM
No special skill/knowledge required to replace sensors
Sensor Color Sensor No errors in electronic changeover compared to manual
changeover

871TM
Inductive Proximity
Sensor
836P
Pressure Sensor
42EF
Photoelectric
Sensor

On-Machine Solution
Sensor configurations stored in the IO-Link master and in Logix
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What is the Benefit of IO-Link?
Multiple Profiles
Multiple profiles: Setup and stored to support multiple machines
Single machine capable of multiple products
EtherNet I/P
Easy change of (package size/packaging) in seconds
Eliminate errors in changeover
No special skill/knowledge required
1732E-8IOLM12R

42JT
Photoelectric 45CRM
Sensor Color Sensor

871TM
Inductive Proximity
Sensor
836P
Pressure Sensor
42EF
Photoelectric
Sensor

On-Machine Solution
Sensor configurations stored in Logix for multiple profiles
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What is the Benefit of IO-Link?
Descriptive Tag Names (Controller Tag View)
Descriptive Tags: The AOP automatically generates Tag Names from
the sensor IO Device Description (IODD) files for IO-Link Process Data
EtherNet I/P
Faster programming for setup
Faster troubleshooting (no generic data [0])
1732E-8IOLM12R Easy monitoring (intuitive tag names)
Ladder logic easier to read

42JT
Photoelectric 45CRM
Sensor Color Sensor

871TM
Inductive Proximity
Sensor
836P
Pressure Sensor
42EF
Photoelectric
Sensor

On-Machine Solution
Sensor I/O data named based on the information it provides
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What is the Benefit of IO-Link?
Real-time Diagnostics (Sensor Health) (AOP View)
Real-time Diagnostics (Sensor Health):
EtherNet I/P During commissioning, easy check of sensor connection / function.
Detection when sensor damaged.
Location indication of sensor fault on machine.
1732E-8IOLM12R

42JT
Photoelectric 45CRM
Sensor Color Sensor

871TM
Inductive Proximity
Sensor

836P
Pressure Sensor
42EF
Photoelectric
Sensor

On-Machine Solution
Real-time monitoring to help ensure optimal sensor performance
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What is the Benefit of IO-Link?
Real-time Diagnostics (Sensor Health)

Real-time Diagnostics:
During commissioning, easy check of sensor connection /
function
Detection when sensor damaged
Smarter machines (dirty lens, misaligned sensor or reflector,
overheating, etc.)
Real-time monitoring features of interest (ie Low Margin Alarm)
Location indication of sensor fault on machine

Real-time monitoring to ensure optimal sensor performance


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What is the Benefit of IO-Link?
Trending
Trending:
EtherNet I/P
Smarter machines (dirty lens, misaligned sensor or reflector,
overheating, etc.)
Real-time monitoring features of interest (Margin, temp, etc.)
1732E-8IOLM12R

42JT
Photoelectric 45CRM
Sensor Color Sensor

871TM
Inductive Proximity
Sensor

836P
Pressure Sensor
42EF
Photoelectric
Sensor

On-Machine Solution
Sensor specific data available in Logix for monitoring
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What is the Benefit of IO-Link?
Application Specific Tag Names (AOP View)
Application Specific Names:
EtherNet I/P
Sensors named based on application theme or location
Location information on machine
(zone1,PE1,BottleCount1)
1732E-8IOLM12R
Reduced commissioning time (mitigate swapped cables)
Sensors on machine easily locatable

42JT
Photoelectric 45CRM
Sensor Color Sensor

871TM
Inductive Proximity
Sensor

836P
Pressure Sensor
42EF
Photoelectric
Sensor

On-Machine Solution
Sensors named based on application them, location
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What is the Benefit of IO-Link?
Timestamping
Process Data input Timestamping
Triggers on Change-of-State (cos) for any of the input data from a discrete input
and/or IO-Link input data mapping
Each channel (total of 8) has one unique timestamp value
Ideal for the Output (Triggered) state of the sensor
Identify when a low margin and/or proximity alarm occurs
Event data Timestamping
Unique Timestamp generated for each event per channel (total of 8)
Most recent event captured for each channel
40 Event buffer for each of the 8 channels to capture event history
Ideal for capturing when sensor is offline/online
Proximity sensor circuit failure (LC Oscillator)

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What is the value of IO-Link?
Timestamping
Process Data input Timestamping
Triggered bit
Track time ON, time OFF, Duty cycle
LowMargin, MarginGood
Monitor when lens became dirty or target moving away from Prox
Plan your maintenance on machine
Event data Timestamping
Sensor disconnected/Connected
Short circuits
Over/under temperature alarms on sensors
Monitor when supply voltages out of spec
Proximity sensor circuit failure (LC Oscillator)
Overall parameter changes
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What is the Benefit of IO-Link?
Universal IO (Input, Output, Analog)

Replace analog input card with IO-Link Master at reduced cost


Replaces analog signal with noise immune digitized signal
Uses standard unshielded cable (no shielded cables required)

No scaling required (digitized signal in engineering units)


Replace output cards for pneumatic valve applications
Can control up to 20 valves thru 1 IO-Link channel
Reduce wiring

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Agenda

Introduction to IO-Link

Benefits of IO-Link

RA IO-Link Portfolio

Use Cases

NEW

PUBLIC Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 25


Product Overview
Allen-Bradley IO-Link Portfolio

IO-Link Masters
1734-4IOL IP20 Point IO (In Cabinet)
1732E-8IOLM12R IP67 (On-Machine)
Photoelectric Sensors
42JT Photoelectric (P-Retro, Diffuse, Thru-Beam)
42EF Photoelectric (P-Retro and Diffuse, T-Beam)
45CRM Color Registration Sensor
45LMS Laser Measurement Sensor
Inductive Sensors
871C Miniature Sensors (3, 4, and 5mm)
871TM Long Range Sensors (12 and 18mm)
871FM Miniature (5x5mm and 8x8mm)
Condition Sensors
836P Pressure NEW

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IO-Link Master
In-Cabinet Solution (Cat. No. 1734-4IOL)

The 1734-4IOL IO-Link Master module enables


connection of up to 4 IO-Link devices or standard IO
Parameterization of IO-Link devices are handled via Add-
On-Profile
(Rockwell Automation and Partner solutions only)

IO wiring topologies between existing POINT terminal


and IO-Link devices are maintained
Supported by all POINT Series B Ethernet adapters (FW
5.012 and above)
Minimum RSLogix5000 V20 and above

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IO-Link Master
On-Machine Solution (Cat. No. 1732E-8IOLM12R)

Enables connection of up to 8 IO-Link devices Process Data Input Timestamping


Triggers COS for all IO-Link and/or discrete
Parameterization of IO-Link devices are
input data
handled via Add-On-Profile
Ideal for Output Triggered state of sensor
Type A IO-Link connectors
Ideal for identifying occurrence of low margin
Supports up to 250mA per sensor and/or proximity alarms
Supports any combination of up to Event Data Timestamping
8 IO-Link sensors, Each event timestamped and logged (for up
8 Digital inputs, to 8 channels)
Available Ideal for identifying occurrence of sensor
8 Digital outputs Aug 2016 offline/online (ex - proximity sensor LC
Oscillator failure)

PUBLIC Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 28


Agenda

Introduction to IO-Link

Benefits of IO-Link

RA IO-Link Portfolio

Use Cases

NEW

PUBLIC Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 29


Use Case
Profiles
Pharmaceutical conveyor line
Line change required 1 time per day (4 lines)
15 sensors on the line need to be re-taught for each line change
Takes 2 individuals 1 hour to complete changeover
Burdened pay rate: $25/hr ($50 per line each day)
Yearly Cost: $50 per line x 4 lines x 265 days per year = $53,000
Product cost = $5/bottle
Lost production/revenue (200 bottles/min x 60 min x 4 lines x $5/bottles = $240,000/day)
With IO-Link sensor changeover accomplished in seconds
New sensor values pushed to each sensor in seconds (set-up values stored in the controller)
Sensors re-taught without error
Limited downtime and limited lost production
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Use Case
Replacing Analog Sensors
Tire Machine with 2 analog pressure and 2 analog temperature sensors
Analog sensors taken into Analog Point I/O Card
4 Shielded cables
With IO-Link enabled pressure and temperature sensors:
Same cost for sensors
IO-Link Master replaces Analog Point I/O
Reduced cable costs no shielded cables required
Qty List Price Total List Price
Current Solution
Analog Point I/O module 1 $ 494 $ 494
Shielded 5 pin cable 4 $ 40 $ 160
Total $ 654

IO-Link Solution
IO-Link Master 1 $ 350 $ 350
Standard Cable 4 $ 21 $ 48
Total $ 398
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Use Case
Locating and Replacing Failed Sensor
Automotive Body and Assembly machine with large I/O count (over 50 inductive sensors)
Today, failed sensors detected thru visual inspection (LEDs)
Can take an maintenance person up to 1 hour to find and replace failed sensor
Lost production: $12,000 per minute x 60 minutes = $720,000
IO-Link able to detect problems before they occur and quickly identify failed sensors
Diagnostic information can be used for preventative maintenance (resolve issues during planned downtime)
Locator indicator can be used to direct maintenance to specific sensor needing attention no wasted time
Lost communications generates event that immediately identifies specific failed sensor
ADC ensures that sensor will be replaced quickly
No specific product knowledge required
Eliminates errors that can occur with manual configuration

Real cost is the cost of downtime/lost production


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Use Case
Simplifying Valve Control
One conveyor line for sorting packages, using around
1200 pneumatic valves
Implemented in 20 sections, each section
containing 4 valve-banks of 14-16 valves each
7-8 output modules (1734-OB8E) to drive 56-64
valves in each section
Special cables/connectors with multiple wires
High labor cost in wiring 1200 outputs
Festo valve-bank with IO-Link Wiring to output modules (without IO-Link)
Replace the above with IO-Link enabled valve-bank from
Festo One UPS line using around 1200 valves
Approx. Qty. List price Total List Price
1 IO-Link module (1734-4IOL) drives 4 valve
Standard Valve-bank Solution
banks, 56 valves
Output module, 1734-OB8E 150 $ 185 $ 27,750
7-8 output modules (1734-OB8E) replaced with 1
1734-4IOL Valve cable/connectors 80 $ 80 $ 6,400
Total $ 34,150
Standard cord sets for IO-Link connections
IO-Link Valve-bank Solution
Cost of materials reduced to 25%
IO-Link module, 1734-4IOL 20 $ 350 $ 7,000
Additional labor cost reduction in wiring Standard cable/connectors 80 $ 21 $ 1,680
(14:1) Total $ 8,680

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Thanks!

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Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 35