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Network and Fieldbus Component Technology

Network and fieldbus components enable smooth communication between devices and ensure efficient data exchange and control in the network. These include IO-Link masters, junction boxes, switches and gateways that reliably transmit data via Industrial Ethernet or IO-Link.

The Most Important Facts at a Glance
Industrial Communication
Definition of IO-Link
Advantages of IO-Link
Communication from IO-Link
Industrial Ethernet
Industry 4.0

The Most Important Facts at a Glance

  • IO-Link is a standardized communication protocol for sensors and actuators.

  • The system components include IO-Link devices, standard cables and IO-Link master.

  • IO-Link masters from wenglor enable connection to Industry 4.0 and IIoT systems.

  • IO-Link 1.1 offers enhanced functionality, improved diagnostics and broader device support.

  • Industrial Ethernet is considered to be the successor to the traditional fieldbuses.

  • wenglor products that comply with the degree of protection IP67 are suitable for decentralized installation outside the control cabinet.

What Does Industrial Communication Mean?

In industry, it is crucial to transmit information reliably. This data transfer enables machines to communicate with each other, control processes, and allows people to work efficiently with machines. A sensor records data such as temperature or pressure in a system and forwards it to a controller. The control system processes this information and sends commands to so-called actuators. Actuators then perform actions, such as starting a motor or turning on a light. They convert electrical signals into mechanical movements or other physical actions. The communication paths and connections in the data transfer can be different. 

What Is IO-Link?

IO-Link (Input-Output-Link) is the first standardized IO technology that enables bidirectional communication with sensors and actuators. The system is based on a point-to-point connection between an IO-Link master and a sensor, with each port of the master having a unique address.

With IO-Link, different data types such as process, diagnostic and parameter data can be read out, providing a comprehensive overview of the condition and function of the sensors. Communication between the IO-Link master and the sensor is bidirectional, which allows both the detection of data and the parameterization of the sensors. IO-Link is suitable for both new construction of industrial plants (greenfield) and for modernization and maintenance of existing plants (brownfield). Even in existing systems, IO-Link can be easily integrated to benefit from the many advantages.

Communication Routes and Connections for Data Transfer

Point-to-Point Cabling

With this traditional connection, the sensors are wired directly to the controller. 
 
Analog signals are susceptible to noise interference
Sensors with multiple measured values require a separate output cable for each value
Converting digital to analog signals reduces signal quality and accuracy

IO-Link Control System

The sensor is connected to an IO-Link master and communicates with the control system in a superordinate network. IO-Link itself is not a fieldbus.
 
Ethernet communication between IO-Link master and PLC enables bi-directional digital data transfer
A 3-core industrial cable transmits multiple process values via a single cable
No EMC interference or signal losses

IO-Link System Components

An IO-Link system consists of three main components: the master, the sensor and an unshielded cable that makes the connection. This simple yet powerful solution enables flexible and efficient integration of sensors and actuators in industrial applications. The IP67 degree of protection makes wenglor products suitable for decentralized use outside the control cabinet.
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IO-Link Master
IO-Link Hub
IO-Link Converter
Sensors with Analog Output
IO-Link Compatible Sensors
Control System (PLC)
Cloud Connection

From Conventional Sensor to Intelligent Sensor

Sensors with analog output provide limited information, as they are usually limited to individual measured values. Transmitting additional data requires more inputs, which increases both wiring effort and costs.

IO-Link technology, on the other hand, enables efficient and seamless integration of sensors into PLC systems and IIoT applications. It reduces wiring effort, increases data diversity and ensures consistent communication. This makes modern automation systems more flexible and future-proof.

The following example illustrates the difference between analog and digital outputs and the data provided by IO-Link compatible sensors.
 

Connection Diagram of a Sensor with Analog Output

Information on process data, such as:

  • Switching outputs

  • Measured values

  • Error Message

  • Contamination information

Connection Diagram of a Digital Sensor

  • Output can have only two states: on or off

  • No additional values or information, only the state “on” or “off”

Connection Diagram of an IO-Link Sensor

  • Cyclic data: Distance value, intensity, clearance value

  • Acyclic data: Simulation mode, configuration parameters, serial number, identification

  • Events: Switching points, teach-in values

*
+ = supply voltage +
– = Supply voltage 0 V
O = Analog output
nc = Not connected
 = Switching output normally closed (NC) 
A/= IO-Link

IO-Link Advantages

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Quick sensor replacement

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Simple initial start-up

Condition monitoring

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Multiple measured values per device

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Remote access to sensor parameters

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High system availability

The Difference between IO-Link 1.0 and 1.1

IO-Link 1.1 was released in 2013 as a further development of the original version 1.0 and brought significant improvements in flexibility and efficiency, especially in applications with complex sensors and actuators. The new version also enabled greater scalability and paved the way for future-proof automation solutions.

 

The difference between IO-Link 1.0 and IO-Link 1.1 is particularly evident in the extended functionality, flexibility and performance of the newer version. The most important new features are:
 

  • Introduction of COM3 (230.4 kBaud) for faster data transfer

  • Extension of the maximum process data length to 32 bytes

  • Implementation of the data storage function for saving and automatic transfer of existing parameterizations to replacement devices

How Does IO-Link Communicate?

IO-Link enables reliable connection of devices to the control system and ensures stable communication. The choice of communication protocol usually depends on the controller, as different protocols offer different properties such as transfer speed and data transfer amount.

wenglor supports IO-Link masters that are compatible with common protocols such as EtherNet/IP, PROFINET and EtherCAT. wenglor’s portfolio also includes sensors with direct Industrial Ethernet connection, such as the PNBC series.

IODD on Board and Data Storage for Parameter Transfer

IO-Link enables the data storage function to transfer the sensor parameterization to a replacement device of identical design when replacing the sensor. This function must be activated and configured in the master.

For PROFINET networks, the wenglor EP8P001 IO-Link master offers the additional IODD on board function for parameterization of sensors. The relevant wenglor IODDS are stored in the GSDML, which can be used directly in the configuration tool for sensor parameterization. This allows parameter data stored on the PLC to be transferred quickly and easily to a replacement sensor.

What Is Industrial Ethernet?

Industrial Ethernet is a further development of the traditional LAN (Local Area Network) used to connect multiple devices in a local network. Numerous devices can be uniquely identified using IP addresses, enabling fast communication and the exchange of large amounts of data. In contrast to standard Ethernet, Industrial Ethernet has been specially developed for use in industrial environments. Among other things, it offers increased security and the possibility of real-time communication, which meets the requirements of modern automation technology.

What Industrial Ethernet Protocols Are There?

For Industrial Ethernet, there are approximately 20 different protocols based on the IEEE 802.3 standard (Institute of Electrical and Electronics Engineers). Each protocol has specific features and benefits, which is why choosing the right protocol is crucial. wenglor offers IO-Link master for the following protocols: 
 
Example of control system manufacturer Siemens Beckhoff Rockwell Automation
Region Europe, global Europe, global USA, global
For Industrial Ethernet, there are approximately 20 different protocols based on the IEEE 802.3 standard (Institute of Electrical and Electronics Engineers). Each protocol has specific features and benefits, which is why choosing the right protocol is crucial. wenglor offers IO-Link master for the following protocols: 
 

Industrial Ethernet vs. Fieldbus

Industrial Ethernet enables communication across all levels, not just at the field level. It is highly flexible and allows large amounts of data to be transferred. In contrast, fieldbuses are specially optimized for real-time applications and impress with their easier installation.

IIoT-Ready for Industry 4.0

The Industrial Internet of Things (IIoT) forms the basis for the intelligent networking and digitization of industrial processes. Efficient and transparent production is achieved through the use of state-of-the-art technologies. IIoT connects devices, machines, and sensors, enabling real-time data and information, such as from manufacturing, to be captured and collected.

IIoT Protocols for Flexible Integration

IIoT can be flexibly adapted to different requirements thanks to modern interfaces and communication standards. Common protocols include:

JSON

JSON enables flexible access to data, including via REST API, which facilitates access via web services. MQTT is a lightweight protocol that ensures efficient communication between devices and applications.

OPC UA

A standardized, manufacturer-independent protocol for secure data exchange in industrial automation.
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