WORLD OF INDUSTRIES 2/2020

how to use this in an uncomplicated and efficient
way for process optimization. What changes with respect
to equipment handling? How does the customer
benefit, what changes for us as a manufacturer,”
summarizes Konrad Meier, Head of
Electronic Design.
This was a reason for the company in 2014
to create the “Integral Connectivity 4”
project: GF Machining Solutions used
this to pursue the goal of implementing
more functional security in the
controller, modular electronic concepts with
decentralized linking of the peripherals, as
well as a simple, thorough communication
solution between the command level and the
sensor/actuator level. No more cumbersome
multi-pin wiring; the installation, assembly and maintenance
effort was to be drastically reduced and the diagnostic capability
increased.
01 Mill P 500 U highperformance
milling center with its
versatile and simply programmable
IO-Link SmartLight stack light
02 8 x ProfiNet/IO-Link master
and IO-Link sensor/actuator hub
from Balluff (right); the cables are
installed via plug-and-play without
the need for tools
Development of an integrated IO-Link concept
“In spring of 2014 we had an opportunity to present the IO-Link
communication standard, which at that time was hardly known at
GF Machining Solutions. Two of the engineers quickly recognized
that this bidirectional interface would provide answers to a variety
of questions. A short time later we got the order to work with GF
Machining Solutions to develop an integrated IO-Link concept for
the planned Mill P 500,” recalls Thomas Zumbrunn, sales engineer
with the Swiss Balluff subsidiary. As a globally standardized IO
standard (IEC 61131-9) IO-Link enables uncomplicated data exchange
between sensors/actuators and the master/control level -
using just the familiar standard 3-conductor cable and M12 connector!
This efficient point-to-point connection is not a fieldbus,
but rather a logical continuation of the previous connection technology
for sensors and actuators.
In addition to many different sensors for position and object detection,
valve terminals and pressure sensors on the rotary index
table including RFID tool management, the Mill P 500 U with its
various feed mechanisms organizes dozens of signals. IO-Link is
in contact with the Siemens and Heidenhain controllers in the
system via Profinet IO-Link masters. “IO-Link offers a previously
unknown simplification from the conception to the installation
and commissioning phase thanks to its standardization. Installation
with IO-Link means error-free plug-in instead of error-prone
wiring. Shielded special cables and expensive plug-in cards are
passé, drag chains undergo drastic reduction, and equipment
with IO-Link guarantees high EMC stability.
Advantages of IO-Link in use
IO-Link really shows its strengths in customer application: a simple
to use central recipe management system allows users to reconfigure
entire sensor groups in seconds from the master or controller
level. The threshold value of a pressure sensor is no longer set on
the device, but rather centrally by the master or from the HMI. Replacing
a defective sensor no longer involves a long system stoppage:
just a few seconds after plugging in the cable the device receives
its relevant values from the central location and resumes its
intended task.
Intelligent sensors are able to transmit a wealth of parameter and
status data in real time, thus creating a comprehensive picture of
the status of things on the process level. This opens up new diagnostic
and predictive maintenance approaches: the milling tool
equipped with an RFID chip sends its specific product and use data
03 Valve terminal plugs connect decentralized valve terminals to the
control level via IO-Link
to the controller and prompts a sharpening date ahead of time.
When a lens gets dirty a photoelectric sensor sends a notification
that performance is being degraded and prompts intervention. A
drive tells the system that a defined temperature limit has been
exceeded. Service and maintenance actions are possible remotely
down to the sensor/actuator level while meeting the operator’s
safety specifications.
Easily visualize every conceivable status
Part of the IO-Link portfolio equipping the new Mill P 500 U is the
SmartLight from Balluff: the IO-Link stack light is freely and easily
programmable, with options for stack light, level, run light and flexi
modes with a broad color spectrum range. “This allows us to easily
visualize every conceivable status, warning message or prompt for
action. And mainly we only need to stock a single, universally
adaptable light type,” emphasizes Konrad Meier.
By using IO-Link GF Machining Solutions and Balluff have shown
that an amazingly simple technology can further refine an essentially
highly precise and reliable process. “Balluff was not just a
parts supplier, but rather a valuable consultant and equal level
project partner. Which is why “IO-Link by Balluff” will be a fixed
part of our offering in the future as well,” summarizes Stefan Fahrni.
Photos: Balluff
www.balluff.com
WORLD OF INDUSTRIES 2020 9