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- IO-Link for PLC
IO-Link in the PLC world
Programmable logic controllers (PLCs) are the backbone of modern automation. However, in times of increasing digitalisation and efficiency requirements, traditional point-to-point wiring is no longer sufficient. What matters today is flexibility, transparency, and modularity – and this is precisely where IO-Link comes in.
More than just a connection.
The technology transforms your PLC into a future-proof control centre with seamless communication down to the field level. IO-Link is more than just a data interface: It is the key to decentralised machine technology and cost-effective, standardised signal processing.
1. Modular, decentralised, future-proof: Systematic machine control
IO-Link standardises signal transmission – from the sensor to the controller. All sensors are connected uniformly via IO-Link masters, regardless of the signal type. This means:
- Every sensor has the same connection – regardless of whether analogue, digital, temperature or pressure
- Parameterisation is performed centrally via the control system
- Modular machine concepts are significantly easier to implement
- Defective devices can be easily replaced without in-depth technical knowledge
This creates flexible, scalable machine architectures with maximum transparency and minimal effort.
2. Fewer cables. Lower costs. More control.
Use IO-Link as an efficient wiring system: With IP67-rated IO-Link master modules, signals can be acquired directly in the field – without a control cabinet or special cabling.
- Standardised M12 cables replace expensive single wires.
- Wiring is reduced by up to 70%.
- Diagnostic and status data is available directly in the master.
- Real-time error detection – no more long downtimes.
The result: Shorter installation times, less material used, and a lower susceptibility to errors.
IO-Link benefits at a glance
Faster commissioning – less effort
Thanks to Plug & Work technology, devices are automatically detected and parameterised. Centralised configuration reduces effort and ensures faster system startups.
Greater operational efficiency
Continuous communication provides real-time data on wear, signal quality, or environmental influences – ideal for condition-based maintenance and maximum system availability.
Modularisation made easy
Decentralised IO-Link masters located directly in the field eliminate the need for wiring to the central unit. Modules can be easily added, moved, or replaced – your machine grows with your requirements.
Standardisation and cost efficiency
IO-Link offers a uniform structure for all signals – regardless of the type or manufacturer of the sensors. This reduces the variety of variants, saves storage costs, and simplifies maintenance.
Traditional point-to-point wiring vs. IO-Link controls system
Traditional point-to-point wiring
Traditional control cabinet size
- Hundreds of terminal connections and wire routes are susceptible to error.
- Typically, 25-30% extra space is built into the control cabinet for future expansion.
- Future expansion requires extensive knowledge to leverage existing cable runs.
Discrete and analogue signals
- ON/OFF and analogue signals from devices are susceptible to noise interference.
- Digital to analogue conversions degrade signal and accuracy from collection to final processing.
Traditional sensors
- If a sensor has multiple values, such as flow and temperature, each value requires its own wire for that output.
- Connection requires home run cables or direct connection, often with hundreds of wire terminations.
IO-Link controls system
Smaller control cabinet using IO-Link
- I/O is field mounted, so cabinet size is reduced.
- Estimated 35% reduction in controls cost.
- Estimated 60% reduction in commissioning time.
100% digital communication
- Ethernet communication between the IO-Link master and PLC provides a bidirectional digital data highway.
- No EMC interference or signal loss, even with long cable runs.
- Pure digital communication reduces data transmission and conversion errors.
Unlock the power of IO-Link
- Most new sensor technology already offers IO-Link communication without increasing the cost of the sensor.
- An industry standard 3-wire cordset carries multiple process values, such as flow rate, temperature, history, and other diagnostics, over a single wire.
- Automatic device replacement transfers configuration parameters from one sensor to another in seconds and minimises downtime in the event of a sensor failure.
