IO-Link® has become the core driving force behind manufacturing industry transformation and is an indispensable component of modern smart factories. It can transform traditional sensors into smart sensors, bringing more intelligence to edge devices. IO-Link enables manufacturers to achieve modernization transformation in their factories without the need to dismantle or replace equipment. This article will introduce the role of IO-Link in smart factories and the IO-Link-related solutions offered by ADI.
IO-Link technology will optimize production lines and simplify production processes
The traditional approach of establishing dedicated production lines for different products has become outdated and financially ineffectual. Utilizing IO-Link master devices as the production core, bringing flexibility and configurability to the factory floor, and enabling self-commissioning sensors and actuators will be a crucial direction for the development of smart factories.
In a manufacturing environment, all manufactured products require an array of sensors to work in coordination to assist machines in tasks such as determining distances to an object, detecting the object, identifying the color and composition of an object, and monitoring the temperature and pressure of an object or liquid. Imagine sending technicians to the factory floor to manually change sensors and recalibrate their parameters to produce a single product – this would consume a significant amount of time and cost. Such inefficiencies would seriously disrupt the entire manufacturing process and result in a comprehensive loss of productivity.
Expanding this approach to the entire production line for different products would require shut down production, then change or reconfigure numerous sensors, incurring significant downtime. Adopting IO-Link technology allows sensors and actuators to undergo changes, enabling self-commissioning and bidirectional communication, further optimizing production lines and simplifying the entire production process.
IO-Link will simplify the development process and reduce time to market
Adopting IO-Link master devices promises to bring intelligence to edge devices. IO-Link masters enable high-speed, bidirectional digital data communication for sensors and actuators on the factory floor. This communication facilitates the development of truly smart sensors and actuators, providing new measurement and monitoring methods that impact every phase of production.
On the other hand, IO-Link simplifies the installation process and interfaces. It uses standardized interfaces, such as the convenient M12 3-pin connector, replacing traditional analog, binary, and serial RS232 interfaces. Besides simplifying the installation process, IO-Link enables users to achieve self-commissioning devices that support automatic parameter setting, making it quick and easy to replace sensors.
Furthermore, IO-Link reduces factory downtime. It offers bidirectional communication, enabling sensors, actuators, and IO-Link gateways to continuously communicate with the Programmable Logic Controller (PLC). It provides real-time diagnostic information and updates, allowing engineers to detect and resolve issues early to prevent disruptions to the production process.
IO-Link also simplifies Ethernet connectivity. To connect IO-Link masters to Ethernet, pre-tested can be done with the second-generation RapID platform (RPG2), which is ADI's industrial Ethernet platform solution, to verify compliance with industrial Ethernet protocol vendor test standards. Designs using ADI solutions can operate smoothly in any supported industrial Ethernet network, simplifying the development process and reducing time to market.
Low-power solution for IO-Link master transceivers
For the applications of IO-Link, ADI launched the MAX14819 Dual IO-Link Master Transceiver with Integrated Framers and L+ Supply Controllers. The MAX14819/MAX14819A are low power, dual-channel, IO-Link master transceivers with sensor/actuator power supply controllers. These are fully compliant with the latest IO-Link and binary input standards and test specifications. In order to simplify the selection of microcontroller, the MAX14819/MAX14819A feature frame handlers with UARTs and FIFOs and can be configured to operate either with external UARTs or utilizing the integrated framer. Additionally, they are equipped with two auxiliary digital input channels, two low power sensor supply controllers, and reverse polarity protection to enable the most robust and low power solutions. MAX14819/MAX14819A is fully compliant with the latest IO-Link and binary input standards and test specifications, IEC 61131-2, IEC 61131-9 SDCI, and IO-Link 1.1.3. This master transceiver also includes two auxiliary digital input (DI_) channels.
The MAX14819/MAX14819A is configurable to operate either with external UARTs or using the integrated framers on the IC. To ease selection of microcontroller, the master transceiver features frame handlers with UARTs and FIFOs. These are designed to simplify time critical control of all IO-Link M-sequence frame types. The MAX14819/MAX14819A also features autonomous cycle timers, reducing the need for accurate controller timing. Integrated establish-communication sequencers also simplify wake-up management.
To accelerate the development of IO-Link applications, ADI has also introduced the MAX14819 evaluation board (EV kit), which includes evaluation circuit board and software. The evaluation board is a fully assembled and tested circuit board that can be used to assess the MAX14819 dual-channel IO-Link master transceiver.
Industrial Ethernet solutions supporting different protocols
ADI has also introduced the ADIN2299 RapID Platform, 2nd Generation (RPG2) network interface for uplink communication. RPG2 is an Industrial Ethernet platform solution that contains all the technology needed to participate in star, line, or ring network topologies, including the communications controller, Flash, RAM, Ethernet switch, and PHYs. It comes complete with multiprotocol software solutions enabling one hardware design to be used across all end systems with different software images to support different industrial protocols.
The host processor connects to the network interface via ADI's unified interface and Ethernet, Serial Peripheral Interface (SPI), or Universal Asynchronous Receiver-Transmitter (UART). The unified interface simplifies communication with any host controller and provides a common interface to support all protocol stacks. This ensures the ability to achieve multi-protocol connectivity without any changes to the application host code, thereby eliminating the design burden of software integration.
ADIN2299 is a pre-tested complete solution for managing industrial protocols and network traffic for application processors. The module includes everything needed to deploy EtherCAT, PROFINET® Real-Time (RT) and Isochronous Real-Time (IRT), and EtherNet/IP networks, including communication controllers, protocol stacks, flash memory, RAM, follower controller, and PHY. Application processors are connected via UART, SPI, or Ethernet interfaces.
ADI has also introduced the EVAL-ADIN2299 evaluation kit for ADIN2299. This evaluation kit provides an end-to-end evaluation of the communication path from the host processor to PLC or PC-based tools. Utilizing this evaluation kit allows for comprehensive validation of the communication path between the host processor and PLC before integrating the network interface into the end-field devices.
Several distinctive IO-Link solutions
In addition to the two main IO-Link solutions mentioned above, ADI offers a range of distinctive IO-Link products, including the MAX14916 compact industrial eight-channel 1A/four-channel 2A high-side switch with diagnostic features. MAX14916 provides eight high-side switches, each capable of delivering up to 1.1A (minimum) continuous current. The two adjacent channels can be paralleled to create four 2.4A high-side switches. These high-side switches have a maximum on-resistance of 250mΩ at an ambient temperature of 125°C.
In addition, there is the MAXM15065, a 4.5V to 60V, 300mA, µSLIC step-down power module. Part of the Himalaya series of regulators and power modules, it offers a low thermal rise, small form factor, and a relatively simpler power solution. MAXM15465/MAXM15466/MAXM15065/MAXM15066/MAXM15067 are part of an efficient, synchronous step-down DC-DC power module series, integrating controllers, MOSFETs, compensation components, and inductors, operating across a wide input voltage range. These modules work in an input voltage range of 4.5V to 60V, delivering up to 300mA of output current.
There is also the MAX32670, A high-reliability, ultra-low-power microcontroller featuring an Arm Cortex-M4 FPU processor, suitable for industrial and IoT applications. Part of the Darwin family, MAX32670 is an ultra-low-power, cost-effective, high-reliability 32-bit microcontroller that allows complex sensor processing designs without compromising battery life. The device integrates a highly flexible power management unit with the powerful Arm® Cortex®-M4 (with a floating-point unit, FPU) processor. MAX32670 also provides a convenient, cost-optimized path for legacy designs upgrading from 8 or 16-bit microcontrollers. The MAX32670EVKIT is the evaluation kit for MAX32670, providing a platform for assessing the MAX32670.
The MAX22514 is a surge-protected IO-Link device transceiver with an integrated DC-DC converter. MAX22514 IO-Link transceiver integrates high-voltage features, including a 24V line driver, an integrated DC-DC buck regulator, as well as 5V and 3.3V linear regulators. MAX22514 is suitable for IO-Link device, master, and industrial switching sensor applications, and it can be configured and monitored via a standard SPI interface.
IO-Link reference designs expedite product development
ADI has also introduced several distinctive reference designs, such as MAXREFDES1458, which is a multi-channel IO-Link master. The MAXREFDES145# is a fully IO-Link®-compliant, 8-port IO-Link master reference design. This design uses TEConcept's IO-Link master stack and is both an IO-Link master reference design as well as an IO-Link sensor/actuator development and test system. Eight IO-Link ports allow for simultaneous testing of up to eight different sensors (or actuators). The reference design has eight robust female M12 connectors, the most common connector used for IO-Link, and ships with two IO-Link cables to quickly connect to IO-Link compatible sensors and actuators. An AC-to-DC (24VDC/1A) power-supply cube is capable of providing at least 125mA simultaneously to each port and more when fewer ports are unused.
The MAXREFDES165# four-channel IO-Link Master is a fully IO-Link®-compliant, 4-port IO-Link master reference design. This design uses the TMG TE IO-Link master stack and is both an IO-Link master reference design and a development and test system for IO-Link sensors/actuators. Four IO-Link ports allow for simultaneous testing of up to four different sensors (or actuators). The reference design has four robust female M12 connectors—the most common connector used for IO-Link—and ships with an IO-Link cable for connecting quickly to IO-Link compatible sensors and actuators. An AC-to-DC (24VDC/1A) power supply is capable of providing at least 250mA to each port simultaneously, and more when fewer ports are used.
The MAXREFDES277# is a dual-channel IO-Link® master reference design optimized for quick prototyping. This design uses the Technologie Management Gruppe (TMG TE) IO-Link master stack for the MAX14819A IO-Link master transceiver and is both an evaluation model for an IO-Link master as well as an IO-Link sensor/actuator development and test system. Two IO-Link ports allow for simultaneous testing of up to two different sensors or actuators.
Conclusion
As industrial manufacturing progresses towards Industry 4.0 smart factories, IO-Link is becoming a critical technology for interconnecting various sensors and actuators, further optimizing production processes on the factory floor. ADI has introduced a variety of solutions for IO-Link applications and offers comprehensive development toolkits and reference designs to accelerate customer development of IO-Link-related products. It's worth exploring and adopting these solutions as they play a pivotal role in the journey toward smarter and more efficient industrial production.