IO-Link simplifies installation and engineering
Since IO-Link was already established in the systems, it made sense to integrate the acknowledgement units into the communication concept. The serial point-to-point connection enables multiple digital signals to be transmitted in both directions.
In this specific application, three acknowledgement stations can be connected via a Class A IO-Link port using just three wires. Compared to conventional hard wiring, the wiring and installation effort is significantly reduced. Furthermore, the M12 connection technology used in the IO-Link environment simplifies installation. Internal machine cabling can be carried out quickly, without the need for complex wiring, and does not require specialist personnel. The integrated diagnostic functions of IO-Link enable rapid fault analysis via the system’s parameterisation interface. In the acknowledgement station developed by SCHLEGEL, the evaluation function can detect lamp failures and monitor the switching cycles of the control elements.
This solution also offers advantages in engineering. Functional adjustments can now often be implemented via the control software, eliminating the need for changes to the wiring or hardware. This simplifies the planning of new projects and subsequent adjustments in the field.
“We had reached the limits of hard wiring. IO-Link has significantly reduced our workload and given us greater flexibility. Since IO-Link was already in use in our systems, it made sense to integrate the acknowledgement stations via this interface as well,” says Reinhold Danner, Head of Automation at Springer.
One solution instead of a multitude of variants
At the start of the project, enclosure variants with two or three mounting positions were under discussion. However, during progress of the development, it quickly became clear that each additional version would increase the workload in terms of design, manufacturing, documentation, and stock management.
The decision was therefore made to opt for a standardised acknowledgement station with three mounting positions. The additional financial outlay compared with a two-position version was minimal, while the added benefit was significant. The standardised acknowledgement stations covers a range of applications, eliminating the need to develop or stock different variants. This reduces complexity throughout the entire product life cycle.
Two normally open contacts per acknowledgement station for flexible interchangeability
The contact configuration has also been consistently standardised. All mounting positions are equipped with two normally open contacts as standard. Whilst a single contact is often sufficient for a pushbutton, two switching contacts are used, for example, in three-position selector switches.
This allows control units to be flexibly interchanged at a later date without any changes to the wiring. The hardware platform remains unchanged; only the control unit used is adapted to the respective application. This simplifies project planning, maintenance and servicing.
Adapted for use on safety guards
As the acknowledgement stations are used on safety guards, design details have also been adapted. At Springer’s request, the enclosure can now only be opened or dismantled using a tool. This prevents the acknowledgement station from being accidentally removed or opened. However, maintenance work remains easily possible thanks to the standardised M12 connector.
Development in just a few weeks
The new solution was developed in close collaboration between Springer and SCHLEGEL. It took just a few weeks from the initial concept to the prototype. This rapid availability made it possible to test the acknowledgement station under real-world operating conditions and to further develop them jointly. The IO-Link-based solution has been in series production since the end of 2024.
“The collaboration was close, hands-on and fast-moving. Our feedback from the field tests was incorporated directly into the ongoing development. SCHLEGEL didn’t simply supply us with a product, but worked together with us to develop the right solution,” concludes Reinhold Danner.
Practical benefits and conclusion
In practice, the benefits of the new acknowledgement statoins are evident on several levels: the amount of wiring required is significantly reduced, as multiple acknowledgement stations are connected via IO-Link. The standardised platform reduces the number of variants in design, manufacturing and spare parts management. At the same time, functional changes can be implemented in the software without having to modify the hardware.
This example illustrates how standardisation and digital connectivity complement each other effectively: a uniform hardware platform reduces complexity, whilst IO-Link provides the necessary flexibility for different machine designs. This approach simplifies engineering, assembly and servicing, particularly for manufacturers of specialised machinery.
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