Remote I/O

With the increasing demand for flexible and scalable automation solutions, decentralised peripherals play a crucial role. They enable optimised use of resources and offer companies the opportunity to adapt their systems more quickly and easily to changing requirements. They also help to reduce the complexity of systems while increasing transparency and control.

By using remote I/O modules, companies can achieve greater efficiency and adaptability in their production processes. Remote I/O (input/output) refers to systems that enable the input and output interfaces of a control system to be located at remote sites. These systems play an essential role in modern industrial automation and process control.

Why is decentralisation becoming increasingly important in industry? And how is LAPP setting new standards with its UNITRONIC® ACCESS product range?

Jürgen Greger, Product Manager Industrial Communication at LAPP, provides exciting insights into the world of remote I/O devices and explains why flexibility and easy integration are crucial. Find out more!

Remote I/O systems consist of modules that receive analogue and digital signals from sensors and actuators and transmit them to a central control unit. LAPP's remote I/O devices, such as the IO-Link master (single and multi-protocol), support various Industrial Ethernet protocols depending on the model, including PROFINET, EtherNet/IP, EtherCAT, Modbus TCP and CC-Link IE. In addition, all IO-Link masters and hubs also support IO-Link itself. The central control unit processes the received data and sends control commands to the remote modules to control various processes.

Remote I/O systems are crucial for automation at the field level. They operate decentrally directly with sensors and actuators without the need for a control cabinet. With interfaces such as sensor/actuator connections, Ethernet connections and daisy chain power supply, they enable flexible and efficient integration into automation systems.

LAPP offers solutions for all levels of the automation pyramid:

1. Field level: Decentralised components for maximum flexibility.
2. Control level: Seamless connection to control systems.
3. Process control level: Centralised control and data analysis.

LAPP offers comprehensive remote I/O solutions that can be seamlessly integrated into existing automation systems. Our solutions cover a wide range of applications, from factory automation to building automation, and ensure maximum reliability and efficiency.

The use of remote I/O systems offers numerous advantages:

Remote I/O systems are essential for modern automation and play a crucial role in numerous industries. They enable signals to be recorded and controlled over long distances and contribute to increased efficiency, reduced costs and improved safety.

Mechanical and plant engineering

• Production facilities: Monitoring and control of production lines, machines and robots in a factory hall.
• Process industry: Control of chemical, petrochemical and pharmaceutical processes where sensors and actuators are distributed across potentially explosive areas or over long distances.

Intralogistics

• Conveyor technology: Control of conveyor belts, cranes and other material handling equipment, such as in packaging technology

Automotive and food industries

• Production facilities: Monitoring and control of production processes

Energy and utilities

• Power plants: Monitoring and control of generators, transformers and switch cabinets.
• Water and wastewater facilities: Control and monitoring of pumps, valves and water treatment plants.
• Oil and gas industry: Remote monitoring and control of drilling platforms, pipelines and refineries.

Renewable energies

• Solar parks: Monitoring and control of solar panels and inverters.
• Wind farms: Control of wind turbines and monitoring of weather conditions.

Patch cords and cord sets are essential for connecting your remote I/O systems. The new portfolio of EPIC® cord sets and EPIC® patch cords from LAPP opens up undreamt-of design possibilities. Newly added cord sets with M5 A-coding, 7/8" and M16 expand the combination options of the existing M8 and M12 portfolio.

For each standard combination of patch cords and cord sets, there is the option of designing them with PUR or PVC sheathing materials. Beyond the standard range, almost any technically possible connection combination can be created, such as a 4-pin M8 A plug to a 3-pin M12 A socket.

By providing all common codings for cord sets, all connection options can now be covered to fully equip remote I/O devices (e.g. L coding, A coding + patch cords).

Remote I/O systems are indispensable components of modern automation and control systems. They offer flexibility, cost efficiency, reduced downtime and scalability, making them the preferred choice in many industrial applications. With the ongoing development of technology, remote I/O systems will continue to play a key role in optimising processes and increasing efficiency.

What is remote I/O and how does it work?

Remote I/O is a decentralised solution for expanding control systems. It enables sensors and actuators to be connected to central control systems via modern communication protocols.

Can I integrate remote I/O into existing control systems?

Yes, remote I/O systems are compatible with many existing control systems and can be integrated without any problems.

What advantages does IO-Link have over other communication technologies such as Ethernet, analogue or digital when it comes to sensor communication?

Unlike analogue and digital communication, IO-Link enables advanced diagnostics of sensors and actuators. In addition, IO-Link devices are easier to commission and replace thanks to automatic configuration and plug-and-play functionality. Compared to Ethernet communication, IO-Link is more cost-effective and easier to integrate.

How are the IO-Link master, IO-Link hub and digital module configured?

The IO-Link master and digital module are configured via a web interface. The IO-Link hub is set up using the IO-Link master. No additional software is required.

What is IO-Link?

IO-Link is a standardised communication system that was developed specifically for integrating sensors and actuators into automation systems. It enables a point-to-point connection between an IO-Link device (e.g. a sensor) and an IO-Link master. IO-Link allows bidirectional exchange of process data and parameters for configuring sensors and actuators. In addition, event and diagnostic data are transmitted to provide feedback on faults or additional information.

More information about IO-Link: IO-Link website of the PROFIBUS User Organisation e.V.

Which cables can be used for IO-Link communication?

Digital signal transmission allows both shielded and unshielded standard cables to be used. The maximum length is 20 m.

Which communication protocols do the remote I/O devices support?

The IO-Link master (single protocol), the IO-Link master (multi-protocol) and the IO-Link hub all support IO-Link.