Three Ways In Which IO-Link Sensors Minimize Downtime

MC-6-Omron-IOLinkSensors-400.jpg

May 18, 2021

IO-Link technology was created in response to three consecutive challenges. The first was the tendency of manufacturers to use whichever I/O system protocol they liked best, causing the devices to not “play well” with those of other manufacturers. To mitigate this issue, some manufacturers began designing fieldbus interfaces into their sensors and actuators.

This solution worked well for some time, but before too long, the size of automation equipment shrunk to the point where fieldbus interfaces would no longer fit into sensors. This second challenge was compounded by a third tendency for automation equipment to become more complex overall, necessitating more types of data collection.

Enter IO-Link, an open network standard point-to-point communication protocol that enables bi-directional data exchange from IO-Link-enabled sensors and other devices. This powerful solution has helped scores of manufacturers increase their data availability, reduce wiring effort, improve machine diagnostics, and easily reconfigure device replacements.

Let’s take a look at a few ways that sensors with IO-Link functionality can help banish the ultimate manufacturing bogeyman: downtime.

1. IO-Link increases data availability.

IO-Link gives manufacturers access to more machine- and process-related data from sensors beyond a simple ON/OFF reading. This data – which might include temperature, measurement, or voltage output readings – can be either analyzed in real time or stored for more extensive trend analysis in the near future.

Because changes in output performance, temperature or other forms of data can correlate to machine health, IO-Link sensors support predictive maintenance strategies that maximize uptime.

2. IO-Link makes device replacement easy and simplifies wiring.

IO-Link provides automated parameter reassignment functionality to let users import parameter values from IO-Link masters into the new sensors that are being used to replace old or damaged ones. Additionally, no special wiring is needed for IO-Link devices. In fact, the protocol reduces inventory costs by cutting down on the types of cord sets required for sensors.

These two features make it quick and easy to replace devices and minimize the amount of downtime required for product changeovers.

3. IO-Link enables remote monitoring.

Operators don’t need to be close to IO-Link devices to read and change their parameters. This can be done remotely via the control system software, making configuration and commissioning time shorter than ever. For changeovers, operators can dynamically alter the parameters from the control system at any point.

Source

Related Articles


Latest Articles

  • Building the Future of Smart Tool Manufacturing – Together

    Why now Is the time to join the AIMS ecosystem August 27, 2025 By Samuel Kirkpatrick, ANCA Senior Product Manager – AIMS The manufacturing industry is undergoing its most transformative shift in over a century. As smart automation, AI-driven production systems, and advanced robotics redefine what’s possible, manufacturers are seeking ways to scale efficiently, adapt… Read More…

  • Comparing maxon EC-i vs ECX Motors: Which One Fits Your Design?

    August 19, 2025 The choice between maxon’s EC-i and ECX motor series depends on whether the application prioritizes torque or speed, rugged durability or quick responsiveness, and high load-handling capability or low-inertia performance. Both maxon product lines use brushless DC motor technology but are engineered with distinct rotor architectures and performance envelopes. This comparison outlines… Read More…


Featured Article

Revolutionizing Material Movement with Autonomous Mobile Robots

Revolutionizing Material Movement with Autonomous Mobile Robots

In today’s fast-paced manufacturing and logistics industries, the need for efficient and flexible material movement solutions has never been greater. Traditional methods like conveyor systems, forklifts, and manual pushcarts have served us well, but they come with limitations.

That’s why Omron is thrilled to announce the launch of their game-changing MD Series of Autonomous Mobile Robots (AMRs). Read more


Products

  • Emergent Vision Technologies Announces All EROS 10GigE Camera Models Now Shipping

    August 27, 2025 Emergent Vision Technologies is announcing that all models of the groundbreaking EROS 10GigE camera series are now officially shipping. Originally launched in December 2024, Emergent Vision Technologies says EROS is the smallest, lowest power10GigE camera in the world. “Thirty-nine new cameras across color, mono, SWIR, polarized, and UV sensors are now available… Read More…

  • Remote Display Unit Type EXCRDU2 from Lovato Electric

    August 26, 2025 LOVATO Electric expands its range of accessories for soft starters and variable speed drives with the new EXCRDU2 remote display unit. It is compatible with LOVATO Electric soft starters ADXL series and ADXNP type, as well as variable speed drives VLB series, equipped with an optional RS485 port. Up to 32 devices can be connected to the same unit, even… Read More…