Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve...

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www.balluff.com Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager Balluff Inc. Florence, KY USA

Transcript of Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve...

Page 1: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Eliminate Errors, Reduce Downtime

& Improve Data Visibility with IO-Link

Will Healy III

Network Marketing Manager – Balluff Inc. Florence, KY USA

Page 2: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

What is Happening on my Factory Floor?

How do I easily track recurring causes

of downtime?

How do I shorten the amount of time

the line is down?

How do I get more utilization and

flexibility out of my equipment?

How do I get maintenance technicians

able to support Ethernet?

How do I know what is happening

now and what happened in the past?

Can I get that sensor with Ethernet?

Page 3: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

www.io-link.com

Page 4: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Universal

• Vendor Neutral & Open Standard (IEC 61131-9)

• Similar to USB's "plug & play" feature

• Uses Existing Infrastructures & Networks

IO-Link is NOT a Network

For Computer

Technology

= For Automation

Technology

Page 5: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Universal – Use YOUR Existing Network Architecture!

Page 6: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Universal – Another Way to Understand IO-Link…

Backplane

Power

Network

Page 7: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Smart

• Store/Change Parameters of Devices

• Reports Detailed Diagnostics

• Provides Event Warnings

Faster

Troubleshooting!

Page 8: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Easy

• 4-wire Sensor Cable

• Parameter Server

• Simple Maintenance

Page 9: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Eliminating Planned & Unplanned Downtime

On The Fly Configuration

• Store settings in the control

• Swap settings as needed

Fast Change-out

• Store settings in the control/master

• Swap smart sensors w/o programming

Page 10: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

The Benefits of IO-Link for a Manufacturer

Page 11: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Eliminate Cabinets & Reduce Arc Flash Hazard Exposure

Page 12: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Case Study: California

I/O I/O I/O

I/O

I/O

I/O

Page 13: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Keep the Network Communicating

IO-Link Masters are out of harms way

IO-Link Slaves are in the danger zone

Reduce the Risk of Network Failure!

Simple Sensor Cables & Protection

Hostile Environment

Worry Free Area

Welding!

Always Connected

Page 14: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Case Study: Kentucky

IO-Link Master

Slave I/O

Slave I/O

Slave Valve

Page 15: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Eliminate Analog Headaches

Old Way

Better Way

Best Way

Humans make

mistakes!

Page 16: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Case Study: Improved Troubleshooting, Diagnostics & Quick-Change

• "Balluff EtherNet/IP Machine Mount I/O products

were selected because it allowed for easier

troubleshooting for my maintenance crews . My

guys on 3rd shift had trouble finding the issue

and they would sometimes make it worse by

fiddling with things inside the controls cabinet."

~Controls Engineer @ Tier Supplier

• 16 points of analog pressure measurement being

converted to IO-Link pressure sensors:

When there is downtime in the factory

and a maintenance guy has to replace

the pressure sensor “they never set it

up right, so then the machine doesn’t

work right and then we have quality

issues.”

Page 17: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Non-Contact Coupling – Technology Overview

0.5 Amps @ 24VDC

Inputs & Outputs

Remote

Base

In-Zone Input Output

Page 18: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Application: Interchangeable Fixtures

– Stop damaging cables

– Stop forgetting to disconnect connectors

– Reduce the Risk of Connector Failure & Slow Bootup!

Jig 230-Right

Jig

23

0-L

eft

Inputs & Outputs

24VDC & 0.5 Amps

No Network Boot Times!

Page 19: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Application: Rotating Table Connections

– Replace Slip Rings

– Devices Powered when Stationary

– Reduce the Risk of Cable Failure & Downtime!

Inputs & Outputs

24VDC & 0.5 Amps

No Slip Ring

Maintenance

Page 20: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Data Visibility: Traceability with RFID

IO-Link RFID is the easiest RFID

to implement in the market, "Tag

is present, data is in the bitmap."

Traceability Enables… enhanced quality

achieve JIT (Just-In-Time)

lean manufacturing

regulatory compliance

Page 21: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Build Data

What are we trying to build?

Data Visibility: Production Control (WIP)

Traceability ROIs with Production Control

• Enable flexible manufacturing

• Track the rework process

• Effectively handle product recalls

• Maintain regulatory compliance

• Manage Work-in-Process (WIP)

Lineage Data

Where did it come from?

Process Data

How well did we build it?

Trick is Tag on

Pallet or Part?

Page 22: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Case Study: Seating Factory

Tracking Build & Process Data

• What are we building?

• Did we build it correctly?

Data Tag

Page 23: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Data Visibility: Asset Tracking (plant based assets)

Sub-Systems Molds & Dies Machine

Tools

Totes &

Containers

Traceability ROIs with Asset Tracking

• Increased asset utilization & productivity

• Assurance that correct asset is used

• Reduction in asset losses

• Reduction in asset's non-productive time

Trick is getting the

Tag on the Asset!

Page 24: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Case Study: Comau Smart Cell

• Quick-Change Robotic End Effectors

• RFID for Tool Identification

• Non-Contact Couplers for Quick-Change

• Discrete I/O Hub for Cylinder & Position Sensors

• Reduced total in-station time

• Improved throughput 15%

Data Tag

Non-Contact Coupler

Page 25: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

IO-Link In Use

• Widely adopted use across many industries,

countries and manufacturers

• Wide Variety of Products in the Market • Pressure, Temperature Sensors

• Measurement & Position Sensors

• Color, Lasers, Light Grid Sensors

• RFID Read/Write Heads

• Valve Manifold Control

• Non-Contact Coupling

• Smart Light Visual Indication

• Discrete & Analog I/O

Page 26: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

What is Happening on my Factory Floor?

How do I easily track recurring causes of

downtime?

How do I shorten the amount of time the

line is down?

How do I get more utilization and

flexibility out of my equipment?

How do I get maintenance technicians able

to support Ethernet?

How do I know what is happening now and

what happened in the past?

Can I get that sensor with Ethernet?

Track IO-Link Provided Data!

Integrate IO-Link Diagnostics!

Utilize IO-Link Parameterization!

They don’t have to, IO-Link is Hot-Swappable!

RFID for history! Smart Light for now!

Can I get that sensor with IO-Link?

Page 27: Eliminate Errors, Reduce Downtime & Improve Data … Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link Will Healy III Network Marketing Manager – Balluff Inc.

www.balluff.com

Eliminate Errors, Reduce Downtime & Improve Data Visibility with IO-Link

Supports YOUR

Network Selection

Replace I/O As

Easy As a PROX!

Troubleshoot

FASTER & Smarter

Get VISIBILITY

into Production

Will Healy III

Network Market Manager

Balluff Inc. Florence, KY USA