IO-Link: Advantages for lighting solutions in machines and systems

Automation and networked production are currently major trends in the industry. However, many of the technical components in use were never designed for a networked environment. Solutions are therefore often more complicated and expensive than they need to be.

The IO-Link standard is intended to change this and simplify many things. How does IO-Link work and what advantages does it offer? Find out in this article. We’ll also show you how to implement lighting solutions in machines and systems with IO-Link.

A simple explanation: What is IO-Link?

IO-Link is a digital interface for communication in automation technology. Sensors, actuators and control units from different manufacturers can be connected to form one complete system and operated via software.

For example, using software you can switch intelligent IO-Link luminaires in a network on and off, control brightness, colour and flashing behaviour, and read out operating data such as temperature and service life.

This enables you to implement a wide variety of automation scenarios, such as: “Flash red if the machine reports an error” or “Reduce the brightness if your temperature exceeds 70 degrees Celsius.” Manufacturers therefore often use IO-Link for machines, systems and automation solutions.

Compared to previous systems that are usually manufacturer-specific, IO-Link boasts many advantages: it is relatively easy to install, cheaper and saves more space, and offers far more possible applications.

IO-Link is on trend

In 2023, 15.9 million new IO-Link devices were installed, corresponding to record growth of 89% over the previous year. The total number of installed IO-Link nodes now stands at an impressive 51.6 million. The growing number of units on the market underlines the success of IO-Link.

Functionality and technical components

In technical terms, IO-Link is a standard for digital, bidirectional point-to-point connections for communication between an IO-Link master and an IO-Link device (International Standard IEC 61131-9).

IO-Link master

The IO-Link master is the system’s central control unit. It establishes the connection between the IO-Link devices and the higher-level control level, such as a programmable logic controller (PLC) or a fieldbus.

A master can have several IO-Link ports, with a device connected to each of these. Communication always takes place as a point-to-point connection between the master and the respective device.

IO-Link devices

IO-Link devices are field devices that are connected via IO-Link. These can be sensors (such as motion detectors and RFID readers) and actuators (such as lights, valve terminals and motor starters).

The devices communicate with the master via IO-Link, send process data and receive parameter and control data. They are also supplied with power via the IO-Link connection.

Connection and connection technology

IO-Link transmits data and power via an unshielded, standardised 3-wire plug-in cable. M8 or M12 connectors are usually used for the connection between master and device. The maximum cable length is 20 m.

Connection to a network

IO-Link acts as an interface between the field devices and the lowest automation level. The actual networking of the automation components takes place via systems such as fieldbuses (e.g. PROFIBUS, PROFINET) or Ethernet-based protocols. IO-Link complements these technologies and closes the gap to the sensor/actuator level, known as the “last metre”.

Typical application scenarios in lighting
Specific application scenarios for IO-Link in lighting include:

• Adaptive lighting in production: adaptation of the lighting to the machining process and the operator
• Status display on machines: lights indicate the operating status, such as production, malfunction, maintenance, etc.
• Lighting control in warehouse shelves: intelligent lights save energy and indicate free storage slots.
• Emergency lighting with evacuation scenarios: in an emergency, lights guide employees safely to the exit.

Advantages and benefits of IO-Link

IO-Link offers a number of advantages for automation solutions. In summary, they can be planned, installed and operated more efficiently.

Simplified, cost-effective cabling

Instead of laying separate cables for power and signals for each luminaire, a single unshielded 3-core standard cable is sufficient as a lower limit. This transmits both the control and parameterisation data (from the master to the luminaire), the operating data (from the luminaire back to the master) and the supply voltage for the luminaire.

The point-to-point connection between the IO-Link master and device also eliminates the complex addressing and termination required for classic fieldbuses. This greatly reduces wiring and installation work, saves space in the control cabinet and reduces the risk of wiring errors.

Manufacturer independence and easier procurement

IO-Link masters and devices from different manufacturers are mutually compatible and can be combined as required. Users are no longer dependent on proprietary solutions from individual providers, but can select the components best suited to their application.

IO-Link reduces the vast number of variants and storage costs for spare parts. Instead of stocking a separate version for each type of luminaire, a few IO-Link luminaires that can be flexibly parameterised are sufficient.

Advanced diagnostic options and remote maintenance

IO-Link devices such as our luminaires transmit extensive status information and diagnostic messages in addition to the process data. For example, operating hours, temperature or the status of the light can be monitored remotely.

This data enables predictive maintenance and servicing. Impending failures can be detected and rectified at an early stage before lighting failures occur. In the event of servicing, IO-Link supports the rapid localisation and rectification of faults by providing detailed diagnostic information.

Parameterisation and configuration via IO-Link

Another advantage of IO-Link is the ability to parameterise and configure devices via the control unit. Instead of having to adjust each luminaire individually on site, parameters such as brightness, colour temperature or lighting effects can be adjusted centrally via the software control unit, even during operation.

This speeds up commissioning and enables the quick adaptation of lighting to changing production conditions. It also makes replacing luminaires easier: the new luminaire automatically adopts the preset parameters.

Less space needed in the control cabinet

By eliminating terminals, relays and fuses for controlling lighting, the space required in the control cabinet can be significantly reduced. Depending on the version, an IO-Link master can connect several luminaires using one compact assembly.

In addition, many IO-Link masters are also available with IP65/67 protection and can be installed directly in the field. In this case, a control cabinet is no longer required.

Functions of intelligent IO-Link luminaires

The TUBELED_25 RGB-W IO-Link from LED2WORK comes with many functions that can be used via IO-Link as standard. It combines powerful workplace lighting and signal lights in one device.

Operating data recording and state monitoring

The luminaire measures extensive operating data and makes it available via an IO-Link connection: including operating hours, temperature and overtemperature log. It continuously monitors its own status and reports when critical values such as the expected operating time are reached.

Individual brightness and colour adjustment

All four channels (RGB + white) can be controlled independently and dimmed infinitely.

Integrated effects

The control unit can be used to activate effects such as flashing, lightning flashing, colour changes and glowing.

Conclusion

IO-Link is revolutionizing networking in industry, including lighting - this can be said with a clear conscience. The standard considerably simplifies the installation, maintenance and control of luminaires. IO-Link also contributes to greater efficiency, for example through predictive maintenance and optimized process control.

Successes and future orientation 

Another highlight of the meeting was the celebration of the impressive market figures. In 2023, 15.9 million new IO-Link devices were installed, a record growth of 89% compared to the previous year. The total number of IO-Link nodes installed is now an impressive 51.6 million. The growing numbers on the market underline the success of IO-Link. At the same time, we have been thinking intensively about how we can drive IO-Link forward in order to meet the constantly changing requirements of the industry.