IO-Link position sensors enable Industry 4.0 environments

The new interface capability allows for sensor connection from an ERP all the way down to the component level – enabling Industry 4.0 and Industrial Internet of Things (IIoT) environments.  

Using IO-Link simplifies the need for designing custom IO boxes to translate various sensor outputs into the fieldbus standard for an application, saving space and development cost.  With this standardised method of communication, the ACW4 and TCW4 sensors can provide digital, point-to-point signals that connect directly to any IO Link Master. 

As IO Link Masters are made with a variety of fieldbus interfaces, the existing fieldbus part of a system can remain the same.  IO Link also provides universal power supply capability, further simplifying the system’s design.

IO-Link features for the ACW4 and TCW4 rotary Hall effect sensors include:

• 24 Volt operation
• Maximum 20m connection length as specified by IO-Link standard
• Enhanced diagnostic and ‘record-keeping’ functions
• Event notification for out-of-spec or warning situations

Bryan Siafakas, Product Line Director of Sensata Technologies’ Industrial Sensing Portfolio, explained: In addition to its compact size, the second generation of this product takes advantage of the IO-Link standard to enable user access to additional diagnostics data from the sensor.  Users can now monitor parameters like internal temperature, running hours, voltage level and synchronisation to identify anomalous conditions.

This diagnostic data allows the operator to better understand the health of the sensor and arrange for planned maintenance, preventing costly downtime. The electronics are contained in an IP65 rated, over-molded plastic shell which keeps them environmentally sealed.

At about 11mm thick, these rotary Hall effect sensors are very compact and flat. The magnet component is separate, and a range of magnet holders is available to fit a variety of installations. This combination of small size and two-part configuration provides developers with additional design flexibility.

"As Sensata continues to expand its solutions in smart technology, new products like the ACW4/TCW4 with IO-Link will deliver more value to our customers as the need for components tailored to automation grows to accommodate Industry 4.0 and Industrial IoT environments," added Naoto Mizuta, Vice President of Sensata’s Industrial business.

The new ACW4 and TCW4 rotary position sensors with IO-Link are ideal for use in robotics and conveyor applications commonly found in inspecting, packaging, sorting and palletising equipment where IO-Link helps maintain a smooth-running system, minimising material loss and improving package accuracy and delivery.