Real-Time Communication without Signal Losses IO-Link at Unprecedented Speed and Accuracy

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SIMTOS (Seoul International Machine Tool Show)

Utilize laser distance and force sensors at full speed: Baumer demonstrates with the IO-Link Master CM50I how fast sensor data improves positioning accuracy and manufacturing quality. Examples from robotics and press-fitting applications prove: real-time communication without signal losses delivers measurable added value in practice.

IO-Link today achieves speeds on par with conventional signals. With additional data, simplified wiring, and easy integration, IO-Link offers crucial advantages for automation processes.

But with these advantages, the potential of the digital interface is far from exhausted. Only the intelligent interplay of sensors, powerful masters, and a manufacturer-independent configuration tool elevates machine performance to a new level: through higher speed and accuracy. Specifically, accuracy—for example, in positioning—increases when communication between the position sensors and the control system occurs more quickly. Additionally, with the IO-Link digital interface, there are generally no signal losses, unlike with analog signals such as 4...20mA. Two practical examples will illustrate this:

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Example Robotics: High-Precision Monitoring of Position and Oscillation

A company pursued the idea of building its own handling systems and robots with modern drives and controlling them directly from the machine control system. However, the developers had to address positioning accuracy and oscillation effects. They sought an easy-to-use system that could ideally monitor the robot precisely in various positions and reliably detect oscillations up to 40 Hz. After a brief analysis, it became clear. The ideal combination was two Baumer OM30 laser distance sensors, which were directly integrated into the EtherCAT control system using the new IO-Link Master CM50I. The advantages of this setup: First, the full 1 kHz measurement frequency of the sensor could be fully utilized, providing additional buffer for frequency analysis. Second, the measured actual values and the target values controlled by the drives could be directly and time-synchronously overlaid, offering additional insights into the complex interplay of the drives with the mechanics. Third advantage: The sensors could be used both for development and for the series machine without further modifications, as the robot was developed directly based on the series-close machine. This completely eliminated the need for a complex prototype with laboratory equipment, which would then have had to be laboriously further developed into a production-ready machine.

Example Press-Fitting Process: Intelligent Monitoring of Series Production

A standard task in manufacturing processes is the pressing of components. Especially with high throughput, it is crucial to determine the maximum manufacturing speed while maintaining the required quality. Here, the rapid exchange of sensor data provided by the Baumer IO-Link complete package of smart sensors, masters, and cables delivers measurable added value. Force sensors measure the pressing force, while high-precision laser distance sensors monitor the position of the part being pressed. The combination of the two results in a force-displacement diagram with distinct force points during the pressing process. This makes it easy to determine whether the resulting forces are within tolerance or becoming excessive. Additionally, during series production, it becomes apparent if a part tilts during pressing, as the forces will spike sharply—especially at displacement positions where hardly any force should arise.

Through near real-time data transmission, developers can easily and quickly fine-tune the optimal machine settings. The Baumer Sensor Suite software provides a straightforward overview of all sensor data. With its intuitive interface, it displays what the sensor detects and allows for the easy parameterization of connected sensors and actuators. The real innovation of Baumer's fast IO-Link complete package in this example lies in the time saved between testing and implementation in series production. The development setup matches the series setup. And because the saved sensor and actuator settings from the test setup can be transferred one-to-one to production, the company loses no additional time.

A core element of the Baumer IO-Link complete package for unprecedented speeds is the IO-Link Master. The latest master generation enables the fastest cycle times, even with real-time capable fieldbus systems like Profinet IRT and EtherCAT. Previously, many IO-Link masters achieved a cycle time of only 10 ms for control. This made Baumer laser distance sensors like the OM30 or force measurement amplifiers like the DAB10, each with a 1 ms cycle time, ten times slower. The new master can achieve IO-Link cycle times as low as 400 µs, and even with Profinet on Siemens controllers, a 1 ms cycle time is reached. This allows the aforementioned IO-Link sensors to be utilized at full performance. This enables precise force-displacement curves, positioning tasks to be performed significantly more accurately or faster, and in the above example, misalignment shutdown can occur very quickly and directly via IO-Link, thus protecting the workpiece and machine from damage.

Faster Engineering With IO-Link

How Designers and Machine Builders Save Time With Smart Sensor Solutions