Balluff Brings Wireless IO-Link to Redefine Control System Networking

Balluff has taken the power of IO-Link and made it easier to use. The sensor company has developed a set of IO-Link communication equipment that is entirely wireless. The newest line of communication equipment includes hubs, bridges, and master network blocks, all of which are geared toward transferring data and commands to automation equipment.

 

Advantages of Wireless Communication

There are some major advantages to using wireless communication between equipment. The ease of installation and reconfiguration will mean quick changes between tooling and products. For example, the simple configuration means a machine can be quickly converted from a prototyping machine cell into full production or vice versa.

 

In this graphic, the robot communicates via wired sensors to a wireless hub, which then transmits data to a wireless network block. Image used courtesy of Balluff

 

Wireless communication means fewer cables to purchase, route, and troubleshoot for faulty connections during operation. Vibration and repetitive motion tend to work connectors apart, leading to rework and scrap in production lines. Cable connectors are often the weakest link, where individual wires break inside the connector. These problems can be difficult to detect, as there may not be a visible sign of damage. Sometimes, the only solution is to buy an extra set of cables for troubleshooting purposes.

 

Balluff Wireless Network Block. Image used courtesy of Balluff

 

Balluff Wireless IO-Link

The newest wireless system by Balluff provides a way to transfer data using well-established IO-Link protocols. A network block can be connected to individual pieces of equipment, and then multiple blocks can be connected through hubs and bridges.

 

Balluff Wireless Hub. The hub can be connected to wired sensors as well. Image used courtesy of Balluff

 

The wireless communication is conducted on the 2.4 GHz band, which requires no special licensing (US, Europe, and Canada) and is high enough in frequency to be capable of high data transfer rates. This frequency band has many well-developed protocols to prevent collisions of data, security from cyberthreats and other concerns that arise in wireless systems.

The Balluff system is capable of polling up to 40 devices with only 5 ms of latency. This means fast, reliable communication between devices. Furthermore, the standard error rate is on the order of 10^-9, meaning data rarely needs to be retransmitted, contributing to the high speeds. This entire system is easily configurable via a web server interface. This also speeds up the deployment and redeployment process of the system.

 

The Future of Wireless Communication in Automation

The ability to move equipment and quickly commission new devices with little cabling headache is a clear advantage over wired communication. All manufacturing industries stand to benefit from wireless communication. The only caveat is that all wireless systems require extra security measures to prevent loss of data or control due to cyberattacks. While secure, technicians and plant engineers who use wireless communication protocols between essential equipment should be well-versed in cybersecurity procedures.

Overall, it has the potential to speed up deployment and redeployment, meaning production can quickly shift to meet changing market demands. It also means prototyping and optimization of processes can be performed much more quickly.