Sensor Technology How to Take Machine Performance to A New Level

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FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

IO-Link offers decisive advantages for automation processes. However, it is only the intelligent interaction of sensors, powerful masters, and a manufacturer-independent configuration tool that elevates machine performance to a new level through higher speed and accuracy.

IO-Link today achieves speeds on the level of conventional signals. With additional data, simplified wiring, and easy integration, IO-Link offers decisive advantages for automation processes. However, the potential of the digital interface is far from exhausted with these benefits. Only the intelligent interplay of sensors, high-performance masters, and a manufacturer-independent configuration tool elevates machine performance to a new level: through greater speed and accuracy.

Specifically, accuracy—for example, in positioning—increases when communication between the position sensors and the control system is faster. Additionally, with the digital IO-Link interface, there are generally no signal losses as with analog signals like 4...20mA. Two practical examples illustrate this.

Example Robotics: Highly Accurate 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. For this, however, the developers had to tackle positioning accuracy and oscillation. They sought an easy-to-use system that could ideally monitor the robot optically with high precision in different positions and reliably detect oscillations up to 40 Hz. After a short analysis, it was clear: the ideal combination is two Baumer laser distance sensors OM30, which are directly integrated into the EtherCAT control system with 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, which even provided additional buffer for frequency analysis. Second, the measured actual values and the setpoint values controlled via the drives could be directly and time-synchronously overlaid, providing additional insights into the complex interaction between the drives and the mechanics. Third advantage: The sensors could be used for both the development and the series machine without further modifications, as the robot was also developed directly based on the series-near machine. A complex prototype with laboratory equipment, which would then have needed to be laboriously further developed into a series machine, was thus completely eliminated.

Example Insertion 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 production speed at which the required quality is still ensured. 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 to be pressed in. The combination of the two results in a force-distance diagram with distinctive force points during pressing. This clearly shows whether the forces produced are within tolerance or becoming too high. It is also possible to later detect in series production if a part becomes misaligned during pressing, as the forces then increase abruptly—especially at distance positions where little force should occur.

Thanks to the near real-time data transmission, developers can very easily and quickly approach the optimal machine settings. The Baumer Sensor Suite software ensures a clear overview of all sensor data. With its intuitive interface, it displays what the sensor detects and allows for simple parameterization of the connected sensors and actuators. The real highlight of Baumer's fast IO-Link complete package in this example lies in the time savings between testing and implementation in series production. The development setup corresponds to the series setup. And because the saved sensor and actuator settings from the test setup can be transferred directly into production, the company loses no additional time.

Significantly Faster or More Precise Positioning Tasks

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. Until now, many IO-Link masters have achieved a cycle time of only 10 ms for control purposes. This makes Baumer laser distance sensors like the OM30 or measurement amplifiers for force measurement like the DAB10, each with a 1 ms cycle time, about 10 times slower. The new master can achieve IO-Link cycle times as low as 400 µs, and even via Profinet on Siemens controllers, a cycle time of 1 ms is achieved. This allows the aforementioned IO-Link sensors to be used with full performance. This enables precise force-distance curves, positioning tasks run significantly more accurately or faster, and in the example above, shutdown upon misalignment can occur very quickly and directly via IO-Link, thereby protecting the workpiece and the machine from damage.

Conclusion: With the new IO-Link Master CM50I, fast IO-Link sensors and actuators can fully realize their potential—for fast and highly precise positioning tasks.

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