WHITE PAPER - IO-LINK WIRELESS - FROM WIRED TO WIRELESS FACTORY AUTOMATION - packREPORT
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
WHITE PAPER
IO-LINK WIRELESS – FROM WIRED
TO WIRELESS FACTORY AUTOMATION
Copyright © 2021 CoreTigo Ltd.
IO-LINK WIRELESS – FROM WIRED TO WIRELESS FACTORY AUTOMATION
WIRELESS COMMUNICATION ON THE FACTORY FLOOR
Mass customization, operational excellence, and business intelligence are fundamentally changing manufacturing. To compete,
manufacturers need machines and production lines that are substantially more flexible, versatile, scalable, and cost-effective.
Maximum adaptivity, higher throughput, and downtime reduction are all common requirements as manufacturers advance
towards Industry 4.0.
Wired communication has long been the preferred option for IO-LINK WIRELESS – A GLOBAL STANDARD FOR
communication on the factory floor, in large part because its WIRELESS FACTORY AUTOMATION COMMUNICATION
high reliability and low latency enabled manufacturers to use
Given the inherent limitations of cabling and the performance
it for machine control as well as for machine monitoring.
gaps of traditional wireless protocols, it became clear that
However, cables limit the flexibility and agility of the machine,
a wireless alternative to IO-Link was needed. IO-Link Wireless
can degrade or break, causing downtime, and are costly to
was developed as a global wireless communication standard
maintain. In addition, wired communication is simply not
designed to replace cables in both remote sensor/actuator
feasible for many motion control solutions that move or
control and monitoring for factory automation. Based on the
rotate rapidly.
IO-Link IEC 61131-9 standard, it is a system extension to the
Traditional wireless communication also falls short, as already established IO-Link-based technology. Like the original
protocols like Wi-Fi, Zigbee, and Bluetooth can’t meet the IO-Link protocol, IO-Link Wireless technology offers high
strict industrial requirements for reliability, latency, and reliability, low latency, scalability, deterministic communication,
scalability. Although traditional wireless is sometimes used for high client density capacity, and robustness, all in a wireless
monitoring, it simply isn’t reliable or fast enough to use for format. It is uniquely suited to meet the demands of Industry
machine control. 4.0 and is already being implemented by some of the world’s
Industry 4.0 needs an alternative solution to provide smart, largest automation equipment manufacturers and
simple, low-cost, industrial-grade wireless communication machine builders.
from the device level (sensor, actuator), to the industrial IO-Link Wireless enables connectivity at the machine level,
ethernet (PLC, industrial PC), all the way up to cloud and with seamless, vendor-agnostic, cable-free communication. It
enterprise applications. expands on the advantages of IO-Link, offering:
• A single wireless communication protocol for both control
and monitoring
“IO-Link Wireless was designed as a • Support for additional applications and systems (such as
rapidly rotating machine components, wireless intelligent
deterministic protocol with a guarantee that
tooling, and mobile systems)
each data packet would be delivered within • Simple and cost-effective deployment for both retrofits and
a bounded delay.” new-builds
• Enhanced flexibility and modularity
• Easy connectivity to the cloud
HIGH PERFORMANCE INDUSTRIAL-GRADE WIRELESS COMMUNICATION
Achieving high-performance wireless communication capable of dealing with harsh factory environments requires a broad range
of design considerations:
RELIABILITY DETERMINISTIC
IO-Link Wireless provides a reliability level of 1e-9 Packet Error IO-Link Wireless was designed as a deterministic protocol with
Rate (PER). In comparison, other wireless standards like Wi-Fi, a guarantee that each data packet would be delivered within
Bluetooth, and Zigbee demonstrate a PER that is 6 orders of a bounded delay. The structure of the IO-Link Wireless cycle is
magnitude less reliable (1e-3). strictly defined, with a limitation on the maximum number of
A repetition mechanism is used for critical data in IO-Link wireless devices per IO-Link Wireless Master. Critical data is
Wireless. To ensure low latency, this mechanism is transmitted periodically in a deterministic manner. The
implemented automatically, controlled by the physical layer of deterministic attributes of IO-Link Wireless ensure predictable
the radio. The repetition is initiated according to ACK\NACK properties of the network and enable algorithms that cannot
and protected by CRC32. be similarly applied with non-deterministic protocols such as
Wi-Fi or Bluetooth.
IO-Link Wireless also uses the Gaussian Frequency Shift
Keying (GFSK) modulation. GFSK is an extremely robust
modulation for dealing with interferences. It confines
emissions to a relatively narrow spectral band, making devices
more immune to noise and more reliable.
2 Copyright © 2021 CoreTigo Ltd.
IO-LINK WIRELESS – FROM WIRED TO WIRELESS FACTORY AUTOMATION
LOW LATENCY 802.11 for the 2.4GHz ISM band, which supports 13 different,
IO-Link Wireless provides deterministic latency of 5msec overlapping frequency blocks. Each blacklisted Wi-Fi channel is
communication with 40 nodes (sensors, actuators, or I/O mapped to a defined blacklist format.
hubs) per Wireless Master. Each IO-Link Wireless cycle of Frequency hopping is used to ensure adequate performance
5msec is comprised of 3 sub-cycles each with a duration of for an IO-Link Wireless system and to reduce the impact of
1.6msec. Each sub-cycle is communicated on a different interferences. Frequency hopping changes the frequency
frequency. The sub-cycle includes a downlink portion which is channels for each transmission as a measure against
broadcasted by the wireless master to all wireless devices on interference, yielding a PER of 1e-9 which is on par with a
the track. The uplink portion is a single-cast time-multiplexing wired connection.
message sent from the wireless devices according to a
A single IO-Link Wireless Master can support up to 40 IO-Link
defined timeslot.
Wireless devices. The Master is divided into five tracks, and
each track in a Wireless Master can support up to 8 IO-Link
COEXISTENCE
Wireless devices.
IO-Link Wireless operates in the unlicensed 2.4GHz Industrial,
All Wireless Master tracks communicate simultaneously on
Scientific, and Medical (ISM) band. Existing wireless networks
different frequencies, enabling optimal network utilization.
will remain active for some time, so new solutions must
In addition, IO-Link Wireless Masters can coexist in the same
coexist with wireless systems that are already installed.
air space.
IO-Link Wireless is designed to coexist with other wireless
networks and interferers through mechanisms such as
blacklisting and adaptive frequency hopping. “A single IO-Link Wireless Master can
Blacklisting is a mechanism designed to avoid potential air support up to 40 IO-Link Wireless devices.
collisions with other wireless systems, such as Wi-Fi. The
blacklist itself uses approximately eighty 1MHz-wide frequency
The Master is divided into five tracks, and
channels. For example, the blacklisting mechanism can be each track in a Wireless Master can support
applied to coexist with a Wi-Fi network according to IEEE up to 8 IO-Link Wireless devices.”
Each Track in each Wireless Cycle is 5msec.,
Sub-cycle is transmitted and it consists of 3 Wireless
on a different 1MHz channel Sub-Cycles (1.6msec. each)
Wireless-Cycle = 5 ms
1st Wireless-Sub-Cycle 2nd Wireless-Sub-Cycle 3rd Wireless-Sub-Cycle t [ms]
2.400
Track 0
Track 1
Track 2
Track 3
Track 4
80 Channels – 2400 – 2483.5 MHz
Track 0
Track 1
2.4GHz Band Frequency
Track 2
Track 3 Downlink portion which is broadcasted
2.450 Track 4 by the Wireless Master to all wireless
devices on the track.
Track 0
Track 1
Track 2
Track 3
Track 4
Uplink portion is a single-cast
˜˜
time-multiplexing message
sent from the wireless devices
according to a defined timeslot.
2.500
f [GHz]
3 Copyright © 2021 CoreTigo Ltd.
IO-LINK WIRELESS – FROM WIRED TO WIRELESS FACTORY AUTOMATION
INTEROPERABILITY POWER CONSUMPTION
Interoperability is critical when adding wireless capabilities to In order to reduce deployment complexity and enable IoT
existing legacy devices or to any device that does not have solutions, sensor and actuator manufacturers are designing
wireless capabilities. IO-Link Wireless uses integration low-power consumption devices that can operate on battery
methods and tools from IO-Link, providing a significant power. Part of the IO-Link Wireless specification is designed
advantage for system integrators and factory personnel. Not for low-energy devices.
only does it support IO-Link devices off the shelf, but it also
supports a wide range of other digital and/or analog devices.
IT / Cloud
IO-Link Wireless
Master
Control & Industrial Ethernet
PLC
Monitoring
IO-Link Wireless Bridge
Sensors &
Actuators
IO-Link Wireless System Typology
“IO-Link Wireless allows products to be
processed in an agile and synchronized
manner while in constant motion. This
eliminates changeover and tooling setup,
reducing downtime and enabling high
capacity and flexible production lines.”
4 Copyright © 2021 CoreTigo Ltd.
IO-LINK WIRELESS – FROM WIRED TO WIRELESS FACTORY AUTOMATION
IO-LINK WIRELESS SOLUTIONS & ECOSYSTEM
CoreTigo’s high-performance wireless solutions are suitable for factory automation in a variety of industries, driving operational
efficiency, adaptive manufacturing, higher availability, and improving business intelligence. CoreTigo IO-Link Wireless solutions
demonstrate a clear advantage in multiple fields, including:
TRANSPORT TRACKS MACHINE RETROFIT
Independent mover transport systems are a key element in Wireless connectivity enables simple and cost-effective
the design of new machines, such as packaging machines. retrofitting and revamping of numerous devices on existing
However, movers are limited as they cannot support real-time machines. It also simplifies relocation, upgrades, and new
communication of actuators and sensors. Cables are not an machine deployment.
option due to the range of motion – therefore, a robust, fast,
and reliable wireless communication solution is required on
each mover.
IO-Link Wireless allows products to be processed in an agile
and synchronized manner while in constant motion. This
eliminates changeover and tooling setup, reducing downtime
Watch Demo Video Read Article
and enabling high capacity and flexible production lines.
ROBOTS/COBOTS
Communication to end effectors on robots and collaborative
robots requires external cabling, cable mounting accessories,
and dedicated wired masters. Robots and cobots do not
typically come with cables for the end effectors, making the
Watch Demo Video See Solution Overview deployment complex and costly. The cables also limit the
motion and flexibility of the robotic arm and add to the total
payload. With IO-Link Wireless, end effectors such as grippers or
vacuum pumps can be easily converted to wireless devices. The
wireless solution eliminates the need for cables and accessories
running along the robotic arms, thus increasing flexibility and
reducing maintenance costs and unexpected downtime.
Read Article
INTELLIGENT TOOLING
CNC, milling, and grinding machines require constant data
transmission while rotating, moving, and cutting at high
speeds in harsh environments with extreme conditions. Cable See here Watch Demo Video
communication and other conventional wireless technologies
are not feasible for data collection in these conditions. An HARSH ENVIRONMENTS
industrial wireless solution enables ongoing data collection to In hazardous and sterile industrial environments such as food &
enable predictive maintenance, data analysis, and machine beverage, wireless solutions reduce the costs associated with
optimization. cabling deployments, maintenance, contamination concerns,
and safety.
Watch Demo Video Read Article
5 Copyright © 2021 CoreTigo Ltd.
IO-LINK WIRELESS – FROM WIRED TO WIRELESS FACTORY AUTOMATION
CONCLUSION LOW LATENCY SCALABLE
The Industry 4.0 revolution is inevitable—there is simply no 1.6 msec (5 msec cycle Up to 40 wireless
other way for manufacturers to meet changing market with 3 repetitions) devices per Master
demands and an increasingly complex global supply chain and
labor market. Full automation is a key component for the
transition to Industry 4.0, but it introduces new RELIABLE COST EFFECTIVE
communication scenarios that require wireless connectivity • 10 packet error rate
-9
Reduce cabling
suited to the industrial space. Existing wireless • 6 orders of magnitude deployment and
communications fall short as they cannot both control and more reliable than maintenance costs
monitor production machinery and do not meet industrial any wireless
standards for latency, reliability, and scalability. • Deterministic
IO-Link Wireless, a global standard based on the ubiquitous
wired communication IO-Link standard for factory automation,
fully meets the requirements of today’s new communication COMPATIBLE FLEXIBLE
scenarios. It provides a proven solution for both new machines Compatible with IO-Link • Increased mobility
and the retrofit of existing equipment and meets the latency
• Roaming
and reliability standards for both monitoring and control.
SIMPLE SETUP
• Easy installation and
configuration
• Scan & Pair
For further information, please contact us at:
info@coretigo.com I www.coretigo.com I +972-747-69-10-20
ABOUT CORETIGO
CoreTigo is unbinding the industrial space by providing high-performance IO-Link Wireless communication solutions for machine
builders, system integrators and industrial equipment manufacturers. CoreTigo’s products enable the design and retrofit of
machines and production lines that were not possible before. These solutions increase flexibility, adaptivity and modularity,
resulting in cost effectiveness, increased productivity and downtime reduction. Embraced by industrial leaders, the IO-Link
Wireless global standard, fit for harsh factory environments and motion control applications, provides cable-grade connectivity
for millions of sensors, actuators and industrial devices worldwide.
White Paper IO-Link Wireless English - Version 1.0 (WPIOLW-EN-01)
6 Copyright © 2021 CoreTigo Ltd.
You can also read
