Retrofit with IO-Link Precision Measurement Technology for the Modernization of Existing Plants

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MICRO-EPSILON Eltrotec GmbH

FAULHABER Drive Systems

SIMTOS (Seoul International Machine Tool Show)

In many manufacturing facilities, machines and equipment remain in reliable service for years or even decades. To ensure their long-term competitiveness, they are increasingly being modernized rather than replaced. IO-Link-enabled sensors from Micro-Epsilon support this gradual modernization by providing additional transparency and digital communication capabilities all the way down to the field level.

Sensors with an IO-Link interface offer significant advantages, particularly in retrofit projects. Existing machines can be upgraded with intelligent sensor technology without having to change the entire system structure. Parameters can be managed centrally, transferred to new sensors, and automatically restored when a device is replaced. This significantly reduces commissioning times and downtime during modernization projects.

IO-Link as a Communication Standard for the Field Level

IO-Link is a standardized communication technology for sensors and actuators in industrial automation. Unlike traditional fieldbuses, it is a digital point-to-point connection between an IO-Link device—such as a sensor—and an IO-Link master. The technology is standardized according to IEC 61131-9 and is based on the proven three-wire sensor and actuator wiring. Therefore, no special cables are required.

The IO-Link master serves as the interface to the higher-level controller. It is used to transmit process, parameter, and diagnostic data. A sensor thus not only provides measurement values but can also supply information about its status, parameter settings, or potential error conditions. This simplifies commissioning, supports maintenance, and increases transparency all the way down to the sensor level. At the same time, IO-Link remains fieldbus-independent and can be integrated into common automation and fieldbus systems via compatible masters.

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How IO-Link Simplifies Plant Operations

Sensors with an IO-Link interface offer users significant advantages during integration and in ongoing operation. Since communication is digital, signal transmission is less susceptible to interference, and the measured values can be processed directly in the controller. Parameters can be managed centrally, transferred to the sensor, and quickly restored when a device is replaced. This reduces setup time and minimizes production downtime.

IO-Link also offers significant advantages during operation. Depending on the sensor, for example, measured value status, signal quality, limit violations, or communication events can be evaluated. This data aids in troubleshooting, simplifies maintenance, and increases transparency all the way down to the field level. This is a decisive advantage, especially for compact sensors in hard-to-reach installation locations. In machines with high component density, in robot cells, or in conveyor systems, physical access to the sensor is often difficult. With IO-Link, relevant settings and diagnostic data can be conveniently retrieved without unnecessarily interrupting the process.

For OEMs and machine builders, the standardized interface offers additional benefits. Sensor designs can be standardized across different machine platforms. This reduces variations in wiring and documentation, simplifies integration, and provides greater flexibility in selecting suitable sensors.

Digitally Surveying Long Distances

Micro-Epsilon offers IO-Link-compatible laser distance sensors for noncontact distance measurements over long distances. These include compact models such as the Opto-NCDT ILR104x, as well as high-performance industrial sensors such as the Opto-NCDT ILR3800, which can measure distances up to 100 m without a reflector and up to 150 m with a reflector.

IO-Link really comes into its own when dealing with long measurement distances. Sensors are often located far away, mounted at a height, or difficult to access. The digital interface allows measurement values, switching points, parameters, and diagnostic data to be managed centrally. This simplifies commissioning and supports reliable plant operation. When modernizing existing crane, warehouse, or conveyor systems, IO-Link simplifies the integration of new sensors. Operators gain access to additional diagnostic and status information without having to fundamentally change their existing control architecture.

Position Control for Crane Systems

A typical application is position monitoring in modern crane systems. One sensor continuously measures the position of the main girder in the X-direction over a range of 0.1 to 100 m, while a second sensor monitors the movement of the trolley in the Y-direction between 0.1 and 25 m. The position values are transmitted digitally via IO-Link to the controller, where they are evaluated together. This allows the current crane position to be reliably determined. At the same time, limit values or operating states can be taken into account. For example, if the trolley approaches an end position, the controller can react automatically and stop the movement in a controlled manner.

Continuous Diameter Measurement of Coils

IO-Link-enabled laser distance sensors are also used in the manufacturing industry, for example in the production and processing of steel strip coils for the automotive industry. As the coils are unwound, the Opto-NCDT ILR3800 continuously monitors the diameter to determine when the coil needs to be changed at an early stage. Thanks to its integrated IO-Link interface, the sensor can be seamlessly integrated into automation systems. This enables precise and wear-free process monitoring even on existing production lines. At the same time, additional diagnostic data is available for maintenance and system optimization.

Compact Laser Sensors for Automation & OEM

Laser triangulation sensors such as the Opto-NCDT 1220 are used for smaller measurement ranges and particularly compact installation situations. The sensor is designed for precise displacement, distance, and position measurements and is particularly well-suited for OEM and mass-production applications. Thanks to its integrated controller, it requires no external evaluation unit and can be integrated into machines and systems in a space-saving manner.

The IO-Link interface is particularly advantageous when multiple sensors are used in a system or when sensors are installed in hard-to-reach locations. The controller can unambiguously map measured values, centrally manage parameters, and automatically adjust them as needed.

Measuring Board Contours

IO-Link really shines when measuring board contours in edging systems. An Opto-NCDT 1220 with a 200-mm measuring range is mounted every 30 to 50 cm to measure the profile of the boards as they enter the system crosswise. By default, measurements are taken from above. Optionally, sensors can be installed on both the top and bottom sides, allowing for flexible board positioning. IO-Link enables the centralized integration, unambiguous assignment, and parameterization of the numerous sensors. Additionally, diagnostic data is available to detect malfunctions early on. As a result, IO-Link not only supports the precise determination of the wood edge for optimal wood yield but also enables preventive maintenance of the system. Especially for older woodworking systems, this approach allows for the retrofitting of additional diagnostic functionality without having to redesign the entire measurement task.

Position and Alignment Control in Vehicle Assembly

Compact laser sensors are also used in vehicle assembly for position and orientation monitoring. The Opto-NCDT 1220 can be integrated directly into tightly packed assembly areas, where it measures distances or heights without contact. This makes it possible, for example, to verify whether a component has been inserted correctly, a carrier is precisely positioned, or a body panel is properly aligned. The measured values are transmitted digitally to the controller via IO-Link and can be used immediately for process approval or correction. Especially in automated production cells with many sensors, centralized parameterization simplifies commissioning and adaptation to different components or variants.

The Foundation for Cost-Effective Digitalization

IO-Link expands the traditional sensor function to include a powerful communication and diagnostics layer, thereby providing ideal conditions for retrofit projects. Existing machines can be modernized step by step without having to replace them entirely. Shorter commissioning times, simplified parameterization, improved diagnostic capabilities, and greater transparency increase system availability and lay the foundation for cost-effective digitalization. Combined with Micro-Epsilon’s precise optical measurement technology, this results in high-performance sensor solutions that allow existing systems to be upgraded efficiently and in a future-proof manner.

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