It would be fair to say that present day IO-Link sensors achieve speeds which are, at the very least, on par with conventional signals. However, the latest IO-Link technology offers decisive advantages in process automation systems, although the potential of the digital interface is far from being fully exploited. Only the intelligent interaction of sensors combined with powerful masters and independent configuration tools can take machine performance to the next levels of higher speed and precision. For example, in terms of precision during positioning improves due to faster communication between position sensors and the control system. Furthermore, with digital IO-Link there is no general signal loss in comparison to analog signals, such as 4…20mA.
Let’s take a look at two specific scenarios…
Robotics: High precision monitoring of position and oscillation
You are a company pursuing the idea of designing your own handling systems and robots utilising the latest drives for control straight from a machine control system. To achieve this, design engineers need to get a handle on positioning precision and oscillation. Ideally this would be the development of an easy-to-use system that would monitor the robot optically in various positions and also at high positions (while in parallel) whilst also reliably detecting oscillation up to 40 Hz.
Sensor specialists BAUMER offers the ideal solution by combining two of their OM30 laser distance sensors integrated into an EtherCAT controller via their new CM501 IO-Link Master. The key benefits of this combination are that it enables the exploitation of the sensors full 1 kHz measuring frequency along with the additional buffer for frequency analysis. Also, the actual measured values combined with the drive-controlled target values can be superimposed and synchronised in real time to provide valuable additional insights into the complex interaction of the drives and mechanics.
Furthermore, as the initial robot development was based on the near series of the machine design, the sensors can be used in the development stage and the ongoing design of the system without the need for further modification - saving valuable development time. This also eliminates the need for an elaborated prototype which may need to be further modified to fit the final machine design.
Press Fitting: Intelligent Monitoring in Series Production
Where processing applications demand high throughput it’s important to determine the maximum production speed and at which the required quality is guaranteed. This is the point where the fast data exchange provided by the all-inclusive Baumer IO-Link package of smart sensors, master and cabling results in added benefits. The force sensors measure the press-fit pressure, while the high-precision distance sensors monitor the position of the part to be pressed in. The combination of both provides a force development diagram with prominent force points during the press fit process which clearly provides information confirming whether the generated force is within the required tolerance or is too strong. Additionally, it will indicate whether a component has been tilted during the process, especially at positions where minimal force is an important requirement.
Data Transmission- in Real-Time.
The ability to allow engineers to easily identify optimum machine configuration is critical in many applications and the Baumer software sensor suite provides a clear overview on sensor data. The intuitive user interface displays what the sensor is seeing for easy parameterisation of the connected sensors and actuators, saving valuable time from the test stage to final implementation in series production. Saving time in the set-up configuration of the sensor and actuator can be adopted 1:1 in series production, eliminating any further loss of time.
In Summary.
The IO-Link is a core element of the Baumer all-inclusive package ensuring unprecedented speed. The latest master generation allows for the shortest cycle times, even in real-time capable fieldbus systems such as Profinet IRT and EtherCAT, compared to conventional IO-Link masters providing feature cycle times of only 10 ms.
This cycle time results in a slowdown by factor 10 in the Baumer laser distance sensors such as the OM30, or force measuring amplifiers like the DAB10 with 1 ms cycle time, whereas the new master is capable of cycle times up to 400 µs on IO-Link side and even 1 ms via Profinet on other conventional sensors. The Baumer combination IO-Link sensors helps users to exploit the entire sensor performance in operation, allowing for precise force displacement curves, speeding up and improved precision of positioning tasks. They also enable direct system switch-off via IO-Link in the event of tilted parts and so prevent both workpiece and machine from damage.
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