Webinar: Retrofit machines to the UNS with IO-Link

Prikshit Rao -

In our latest webinar, Mateusz and Alexander explored how IO-Link sensors provide a cost-effective, efficient, and scalable solution for retrofitting machines. By bridging the gap between legacy hardware and cutting-edge software, manufacturers can unlock valuable insights, improve operational efficiency, and lay the groundwork for digital transformation.

Webinar Agenda

Introduction
- Overview of our platform and architecture
- Benefits of using a Unified Namespace for Industrial DataOps

Connecting IO-Link to the UNS
- Background and challenges
- Demo environment and setup
- Configuring connectors for:
- Temperature (as environmental data)
- Light Barrier (as a product counter)
- Vibration Sensor (as a machine state indicator)

Data Visualization
- Visualising data points
- Easy data collection in the field through IO-Link: Plug and Work technology also for non-control engineers
- Benefits for operational efficiency

💡
If you want to learn more about our product and try out the free community version, you can visit our website.


Transcript

Mateusz: Hello everyone, welcome to another United Manufacturing Hub webinar. This is the third session in our series, and I’m thrilled to have you all here. The previous webinars were quite successful, with engaging questions from our community.

Today, we’ll focus on retrofitting your machines with IO-Link sensors. Let’s start with introductions. My name is Mateusz, and I’m the Customer Success Manager at UMH. Previously, I worked in digital transformation for a consulting firm for five years. Now, I’m here to help customers pilot and scale their implementation processes. Joining me is Alex, our Co-Founder and CEO.

Alexander: Thank you, Mateusz. For those who don’t know me, I have a mechanical engineering background but transitioned to IT quickly. Before founding UMH, Jeremy (our CTO) and I ran a system integration business. We often faced challenges in getting data from shop-floor machines because machine vendors either charged high fees or had restrictive policies. This inspired us to explore IO-Link technology, enabling us to fetch essential data points from machines efficiently. Today, we’ll share more about how to use IO-Link sensors to connect even the most challenging machines.

Retrofitting Overview

Mateusz: For those new to UMH, let me provide a quick background on our vision and approach. At UMH, we aim to bridge the gap between IT and OT by consolidating diverse data streams into a unified namespace. This involves integrating data from machines, MES systems, PLCs, and more, creating context-rich, human-readable formats. Using event-driven architectures, we simplify data flow and reduce reliance on point-to-point connections.

Alexander: Back in 2019-2020, while working in industries like semiconductor, metal cutting, and automotive, we encountered many non-connectable machines. For example, in pharmaceutical environments, regulatory restrictions prevented us from modifying machines. To overcome this, we used external sensors like light barriers to count products and button bars for shop-floor interactions. These creative solutions helped us extract actionable data without compromising compliance.

Alexander: Initially, we relied on classical analog sensors. However, they required extensive calibration, making them inefficient for large-scale deployments. IO-Link sensors revolutionized this process by providing context-rich, human-readable data out of the box. This eliminated the need for manual data interpretation, allowing us to connect sensors more effectively.

Mateusz: IO-Link sensors are plug-and-play, but integrating them into a broader data ecosystem requires the right tools. Let’s demonstrate a simple setup using a conveyor belt retrofitted with IO-Link sensors.

Demonstration: Conveyor Belt Setup

We retrofitted a conveyor belt with the following:

  1. Vibration Sensor: Detects if the motor is running.
  2. Proximity Sensor: Identifies when a hatch is open.
  3. Light Barrier Sensor: Tracks product counts.

These sensors connect to an IFM AL 1350 IO-Link Master Gateway. Data is transmitted via Ethernet to our unified namespace using RESTful APIs. The IO-Link sensors provide human-readable JSON structures for seamless integration.

Mateusz: We’ve also enriched our software with automatic detection and configuration of IO-Link devices. For example, our system fetches IODD files (device descriptors) to interpret sensor data accurately.

Alexander: This setup ensures easy scalability and minimal disruption to existing workflows. It’s a reliable middle ground between fully manual tinkering and expensive system integration.

Practical Insights

Mateusz: When retrofitting machines, common challenges include selecting the right sensors, ensuring safe installation, and maintaining compliance. For example, retrofitting older machines with basic performance monitoring sensors can still provide valuable operational insights.

Alexander: In cases where machine vendors are uncooperative or charge high fees for data access, IO-Link sensors offer a cost-effective alternative. With proper implementation, you can achieve significant cost savings and improved data availability.

Questions from the Audience

Q1: How does retrofitting affect CE certification?

Alexander: External retrofitting does not impact the machine’s CE certification since it does not involve internal modifications. All components we use are CE-certified.

Q2: Can data flows be encrypted?

Mateusz: Yes, our setup supports HTTPS for secure data transmission. However, encryption in OT environments requires careful management of certificates and keys.

Q3: What about connecting CNC machines?

Alexander: CNC machines are often proprietary. Start with standard interfaces like OPC UA or Modbus, and avoid custom integrations unless absolutely necessary.

If you’d like to explore these solutions further:

  • Visit our website for more resources.
  • Join our Discord community with over 900 members.
  • Contact us for one-on-one discussions about your specific use cases.