Condition Monitoring and Predictive Maintenance with IO-Link Rotary Encoders
Whether in the material handling industry, in packaging machines, or in wind turbines—sensors with IO-Link interface are increasingly being used to pave the way to Industry 4.0. With the ENA**TL-**IO-Link, Pepperl+Fuchs was one of the first manufacturers to launch an absolute rotary encoder with IO-Link interface, which is available in numerous variants and with a wide range of setting parameters. In our blog article, you will learn how you can benefit from easy configuration and integration with this IO-Link rotary encoder, while at the same time monitoring the status of your plants in a cost-effective manner.
Why Rotary Encoders with IO-Link?
The internationally standardized IO-Link interface enables continuous communication between the control level and the individual sensors at the field level. Sensors equipped with IO-Link not only fulfill their actual sensor function, but also create the basis for systematic diagnostic concepts. Therefore, the condition of machines can be continuously monitored so that failures and downtimes can be prevented through predictive maintenance.
The use of intelligent, communication-capable rotary encoders is an easy way to implement condition monitoring and predictive maintenance: this way, no high investments are required for retrofitting the plant. Since other sensor technology, for example in material handling technology, is also increasingly being converted to IO-Link, the IO-Link rotary encoder fits seamlessly into the overall concept of many industrial plants. Furthermore, the measured values are transmitted at a speed of 230.4 kBit/s via COM3—the highest transmission speed in the IO-Link standard.
Pepperl+Fuchs offers a wide range of IO-Link rotary encoders in different mechanical variants that can be implemented in all common applications for absolute rotary encoders. Due the magnetic detection principle, the sensors are robust and wear-free, and precisely detect the rotation angle of the encoder shaft. In addition, the ENA**TL-**IO-Link comes with a multitude of sophisticated functionalities:
- The multiturn function enables the mapping of cyclic applications.
- The preset function allows position values to be adjusted during operation. This way, inaccuracies caused by slip can be compensated for without the need for time-consuming readjustment.
- The rotary encoder not only measures position values in rotating movements, but also temperature values. This makes it possible to draw conclusions about the condition of the machine.
- Critical position and temperature ranges—so-called signal flags—can be individually defined. As soon as a critical value is reached, the machine can be switched off automatically.
The absolute encoder with IO-Link interface provides high-precision measurement data and is characterized by its robust design. With the ENA**TL-IO-Link, you have all the advantages of an IO-Link interface at your disposal: easy parameterization, simplified maintenance and complete data transparency.
Easy Commissioning Due to IO-Link
The IO-Link interface not only enables condition monitoring and predictive maintenance, but also facilitates configuration and integration of the rotary encoder. Via an IO-Link master, the ENA**TL-**IO-Link can be parameterized more quickly and easily than conventional rotary encoders. The IO-Link master offers extensive configuration options: the parameters can be easily adapted via software tools. On request, the rotary encoders can also be delivered with customer-specific parameter adaptation, even in small quantities.
Our customers also benefit from the advantages of the IO-Link interface when replacing the sensors: Since the setting parameters are stored both in the rotary encoder and in the IO-Link master, there is no need for time-consuming re-parameterization. This saves time when replacing sensors in existing systems.
Three Practical Application Examples
Typical applications for the ENA**TL-**IO-Link are positioning and length measurement tasks, for example on conveyor belts, cranes, elevators, and packaging machines. In the following, you will learn more about three practical application examples.