IO-Link Sensors help you digitalise industrial processes

IO-Link is the future of production and testing technology. Smart features and digital sensors that enhance accuracy, reliability and efficiency, are ideal for automation and testing applications.

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How does IO-Link work?

IO-Link sensors are connected to IO-Link Masters, which in turn can be integrated into any existing industrial fieldbus environment. This flexibility, as well as the robust IO-Link topology, makes IO-Link systems scalable and adaptable to various control system architectures.

A single standard, unshielded, three-wire cable is used both for power supply and data transfer purposes for an IO-Link device, reducing the complexity and cost of cabling.

IO-Link technology marks a new era for sensors in mechanical applications, enhancing accuracy, reliability and efficiency – all while lowering your business costs

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IO-Link Commercial Benefits
IO-Link Technical Insights

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Learn how IO-Link smart sensors can help you reduce costs, improve efficiency and achieve your business goals

Investing in IO-Link technology isn’t just about keeping up with the times; it’s a strategic leap towards modernising manufacturing processes. But what is IO-Link? How do smart sensors work? And how do they enable instant cost savings and help your company gain a competitive edge?

Discover how IO-Link and our portfolio of IO-Link sensors can transform your manufacturing landscape – efficient, reliable, and future-proof.

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White paper: Enhance your efficiency with strain gauge-based smart sensors empowered by IO-Link interface

Discover the full potential of our strain gauge-based smart sensors with the IO-Link interface in our white paper from HBK’s key experts.

Download now to gain invaluable insights into enhancing efficiency and precision in your operations!

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Pre-processing measurement data for process control simplifies customer applications and cuts costs. Integrated sensor health monitoring ensures safe operation and minimises machine downtime.

Closing the communication gap between control and field levels facilitates remote problem analysis, troubleshooting and minimises downtime.

IO-Link, which is based on IEC 61131-9, consolidates the variety of field-level signals, thereby simplifying the design of machine systems. Its fieldbus independence enables easy integration into all common PLC architectures.

Easy, cost-efficient integration into your existing infrastructure

Infographic with typical setup of an IO-Link system in combination with force, load cell and torqu transducer.

Advantages of digital IO-Link sensors

With built-in amplifiers, IO-Link sensors eliminate the need for external measurement amplifiers. Direct connections to decentralised IO-Link masters save on cabinet space. Standardised cabling also significantly reduces complexity and cost.

IO-Link reduces costs by simplifying training needs and maintenance tasks. By using standardised M12 connectors for devices and masters, along with a standardised device integration process, system complexity is minimised, leading to reduced training requirements for employees.

Eliminate data overload, increase your decentralisation options and error analysis features and enjoy a seamless communication between sensors and IT systems. The flexibility offered by IO-Link sensors reduces system complexity and facilitates easy adaptation to different PLC architectures, ultimately enhancing operational efficiency.

HBK IO-Link sensors address critical industry challenges. They monitor sensor health factors like temperature and load limits, preventing costly machine breakdowns. Our traceable calibration services for force and torque sensors meet ISO 17025 certified standards and feature accurate amplifiers and advanced scaling options. Our sensors meet diverse measurement needs and achieve enhanced accuracy when combined with calibration data.

Illustration of an infographic showing smart functions and features with smart sensors in isometric perspective

Simplified measuring chain

Benefit from smart, domain-specific features across force, load and torque

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Force
Load
Torque

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Overview of smart force sensors with IO-Link

Available sensors: digitalised counterparts of proven passive tensile and tensile and compression force sensors now available with IO-Link. Portfolio is permanently expanded
Sensor health monitoring: force sensor specific static and dynamic mechanical and thermal limit monitoring, and warning event triggered when exceeded
Analogue process control: one digital Out (additional digital Out available when IO-Link data transmission is disabled)
Domain-specific features: 40 kHz internal sampling rate for high dynamic sensing and pre-processing, linearisation (table, polynomial)
Domain-specific algorithms: peak value detection, span detection, limit switches, two filter stages (Bessel, Butterworth)
Calibration service available in accordance to the international standards. HBK Service: calibration used to linearise your sensor, data already entered on arrival at your facility

HBK IO-Link Force Sensor Products:

Overview of smart loadcells with IO-Link

Available sensors: 14 digitalised counterparts of proven, passive, single-point load cell types now available with IO-Link
Sensor health monitoring: load cell specific static and dynamic mechanical and thermal limit monitoring, and warning event triggered when exceeded
Analogue process control: one digital IO, (additional digital IO available when IO-Link transmission is disabled)
Domain-specific features: weighing technology filters (up to five-stage filter cascade)
Domain-specific algorithms: filler and checkweigher algorithms
Factory scaling implemented on delivery, additional teach-in assistant for mounted cell calibration with proofing weights

HBK IO-Link Load Cell Products:

Load Cell Measuring Chain (LCMC)

Proven T210 shaft torque transducers for measurements from 0.5 Nm to 200 Nm and up to 30,000 rpm now available with IO-Link
Sensor health monitoring: sensor-specific monitoring of static and dynamic mechanical and thermal limits, triggering warning events when these limits are exceeded
Analogue process control: one digital Out, (additional digital Out available when IO-Link data transmission is disabled)
Domain-specific features: auxiliary information (rotational speed, angle, temperature (rotor/stator), linearisation (table, polynomial)
Domain-specific algorithms: power calculation, peak value detection, span detection, limit switches, two filter stages (Bessel, Butterworth)
Calibration service is available in compliance with international standards. HBK Service offers calibration to linearise your sensor, with data pre-entered upon its arrival at your facility

HBK IO-Link Torque Sensor Products:

T210 shaft torque sensor

As a digital technology, IO-Link is set to be the predominant interface for field-level sensors for many years ahead, providing customers with a future-proof solution. Our portfolio of IO-Link sensors spans multiple domains, reflecting our commitment to this enduring technology. As industries evolve towards incorporating smart sensors in manufacturing processes, our extensive experience in sensor solutions drives product innovation through virtual, physical, and in-process testing across the product life cycle.

Webinar: Why digital sensors are the future - force, torque and load with IO-Link

Download this webinar presentation to learn about state-of-the-art digital sensors and their advantages. You’ll discover why the proven IO-Link technology for the classic HBK domains is the ideal interface for automation and testing applications.

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FAQ | Answers to your questions about HBK IO-Link sensors

The new integrated amplifier module offers numerous features that significantly improve the quality of your force measurement:

Linearisation functions
Two limit value switches
Freely adjustable low-pass filters (Bessel and Butterworth)
A single fixed digital output (DO); an additional digital output is optional in standard input/output (SIO) mode
Sensor health monitoring: warning in the event of critical operating states. (static and dynamic overloads, temperatures outside the specification)
Statistical functions (min/max memory, average values, number of measuring points, etc.)

Linearisation functions

You can linearise using interpolation points or cubic linearisation functions. The programming is done in such a way that results from standardised calibration certificates (ISO 376, DKDR3-3) can be entered very easily. Of course, you can also perform linearisation using your own reference measurement. It is possible to work with reference points for this purpose.

Freely adjustable low-pass filters (Bessel and Butterworth)

The cut-off frequency of the filters can be entered easily by typing the cut-off frequency as a numerical value into the software. These are sixth-order digital filters.

Two limit value switches

The limit value switches are programmed according to the specifications of the IO-Link Smart Sensor Profile. In addition to the threshold value, you can define a hysteresis if your process requires this. The so-called ‘window mode’ is also available. Here, a limit value switch is activated when the measured value is within a range defined by you, for example, between 1 kN and 1.8 kN.

Both switches can be negated.

One fixed digital switching output, one switchable switching output

A single IO-Link digital output is always available so that results can be obtained quickly at the digital switching output. The output switches at a maximum of 0.35 ms going high after a threshold value is exceeded or low if the threshold is undershot. You can deactivate the transmission of the IO-Link communication and use the line that becomes available as a second digital output (SIO Mode). The force transducer then becomes a force switch with two switching points.

Sensor health monitoring: warning in the event of critical operating states (static and dynamic overloads, temperatures outside the specification)

During production, all essential sensor properties are stored in the amplifier:

Highest operating temperature/lowest operating temperature
Limit temperature electronics
Processor limit temperature
Highest nominal force/lowest nominal force
Maximum operating force/minimum operating force
Highest nominal temperature/lowest nominal temperature
Maximum peak – peak value (amplitude)

The electronics constantly compare the force and temperature values with the limits and report any overruns so that appropriate action can be taken.

Statistical functions (min/max memory, average values, number of measuring points)

All statistical functions are determined at a measuring rate of 40 kS/s. This is particularly useful for the min/max values.

Our IO-Link sensors work at a high measuring rate and support the fast IO-Link COM3 standard.

HBK utilises the COM3 transmission rate and, therefore, the fastest possible data rate in the IO-Link world. Internally, the amplifier module operates at 40 kS/s, so that even highly dynamic signals are stored correctly in the peak value memories.

This question has two aspects.

Firstly, the signal runtime in the HBK electronics has a maximum duration of 350 µs. This means that it takes 0.35 ms for a physical event (a signal change) at the input of the amplifier to be available at the output of the amplifier module.

To determine the maximum signal propagation time, the cycle time specified by the master is an important parameter. If we assume that the master works with a cycle time of 2 ms, the maximum latency time would be 2.35 ms until the signal is available to be processed in the IO-Link master.

The output at the digital switching outputs is only determined by the latency of the amplifier module: here, the runtime is 0.35 ms. Please note that filters extend the signal runtime.

Secondly, the bandwidth of the measurement chain depends on the stiffness of the sensor, the installation conditions (coupled masses, stiffness of the force inputs) and the number of measured values/time unit. The amplifier module is able to realise a cycle time of less than 1 ms. This means that 1 kS/s can be transmitted. A rule of thumb says that the bandwidth of the measurement corresponds to about 1/10 of the measurement rate, so a bandwidth of 100 Hz is feasible. The cycle time is specified by the IO-Link master.

The bandwidth, which is decisive for the maximum and minimum value memory, is significantly higher. The module has an internal sampling rate of 40 kHz. This corresponds with an internal bandwidth of 4 kHz.

The IO-Link interface can be integrated into all common fieldbus architectures and makes commissioning very easy!

An IO-Link master serves as a node to which the individual IO-Link sensors are connected in a point-to-point connection. IO-Link masters serve as gateway modules for integration into the automation level. IO-Link masters are available for all fieldbus and industrial Ethernet protocols. This means that HBK force transducers, load cells and torque transducers, along with many other sensors or actuators, can now also be connected easily and efficiently with the IO-Link interface into customers' control system architectures.

IO-Link uses an inexpensive, unshielded cable to ensure reliable and interference-free data transmission (at 24 V) and power supply. This very flexible cable has no mechanical influence on the measurement, even when very small loads are involved. As there is no shielding, the housings of the HBK IO-Link sensors and the IO-Link master are galvanically isolated from each other.

Yes, the same services are available for the new generation of digital IO-Link force and torque sensors in the accredited HBK laboratory as for the analogue sensors. The traceability of measurement equipment required by ISO 9001 is therefore guaranteed.

HBK has a calibration laboratory accredited in accordance with ISO 17025. Calibration at HBK meets the requirements of the relevant quality standards, including ISO 9001. Digital sensors are calibrated on the same equipment that is used for analogue sensors. This means that customers who have opted for IO-Link as an interface benefit from the exceptionally high accuracy of HBK force and torque calibration machines.

The calibration procedure is slightly different.

In the initial stage, the sensor's stored linearisation data is read out and saved. This applies to the stored coefficients of a compensation function as well as any interpolation points that may have been entered.

Following that, all linearisation coefficients or interpolation points are deleted and the linearisation function is switched off. The amplifier now works linearly.

Finally, the sensor runs through a force or torque series, and the linearisation coefficients are determined and entered into the sensor.

Calibration is carried out according to the standard, according to customer requirements, and in accordance with ISO 376 or DKDR3-3 for force, or DIN 51309 and VDI/VDE 2646 for torque. Factory calibration certificates are also available.

The sensor is delivered as a linearised measurement chain. The calibration certificate specifies the measurement uncertainty of the overall system. The original characteristic curve is calculated from the stored coefficients so that the entire history of the sensor is available to you.

Cost savings, simple set-up and communication right down to field level. Increased operational reliability – the IO-Link advantages speak for themselves!

The cost advantage is one of the greatest benefits. IO-Link technology offers cost savings by eliminating the need for an amplifier in the control cabinet. Additionally, cabling expenses are significantly reduced due to standard IO-Link cables. Furthermore, the time-consuming process of parameterising the conventional measurement chain is eliminated. With IO-Link sensors, measured values are directly output in the appropriate physical units (N, kg, Nm, etc.) without the need for time-consuming parameterisation.

Additional IO-Link benefits result from improved operational reliability: digital signal transmission is less sensitive than previous analogue technologies, and the sensor continuously monitors applied loads and temperatures, issuing warnings before any damage occurs.

Of course, it is very helpful to be able to communicate from the control level to the interface to the process - the sensor.

HBK IO-Link sensors with an IO-Link interface achieve very high precision for industrial use.

As the sensors have an integrated linearisation functionality the characteristic curve errors can be reduced and are therefore smaller. With IO-Link force sensors, for example, the tension/compression characteristic value difference can be corrected, which results in a higher accuracy.

The IO-Link amplifier module has a low signal/noise ratio and the digital signal transmission prevents cable influences. All in all, these smart industrial sensors gain accuracy in standard industrial applications.

No, leveraging the IO-Link interface, HBK is able to integrate intelligent process algorithms into mechanical quantity measuring sensors like force, load and torque sensors. This enables standardised commissioning for customers, ensuring ease and efficiency.

IO-Link technology has its origins in the field of switching sensors and, over the last few years, has established itself as the industry standard for digital sensors. In more recent years, measurement sensors and control elements such as actuators have also been increasingly equipped with IO-Link technology. Based on high-performance microelectronics, it is now possible to integrate HBK's domain-specific algorithms directly into sensor electronics:

Filters (Bessel, Butterworth, multi-stage filter cascades)
Linearisation functions (table, polynomial)
Compensation algorithms
Sensor health monitoring (tracking mechanical influencing variables on the sensor)
Process algorithms (filler, checkweigher, min/max, limit switches, power calculations for torque sensors and more)

This enables the sensor to operate with extensive measurement data pre-processing and process control capabilities. The IO-Link interface now serves as a communication interface to transmit these pre-calculated results, the added value of information (alarms, events) and the measurement value data with a cost-effective and universally applicable interface technology. IO-Link is the perfect communication interface for smart sensors in the field of physical and mechanical quantities such as force, weight and torque.

The new amplifier module offers numerous features and functions that significantly improve the efficiency and performance of your weighing applications:

Two-point scaling or in process adjustment (calibration process/teach-in)
Two limit value switches
Up to five filter stages can be cascaded: FIR, IIR and comb filter as well as moving average
Process algorithms: integrated filler and checkweighing algorithm
One fixed digital switching output, one optional switching output
Sensor health monitoring: warning in the event of critical operating states (static and dynamic overloads, temperatures outside the specification)
Statistical functions (maximum, minimum, peak-to-peak)

Two-point scaling and calibration assistant

You can store a two-point scaling by entering it manually. There is also a calibration/teach-in assistant that can be used to calibrate using reference weights.

Filters for weighing applications

It is possible to use up to five filters in a filter cascade. In the initial stage, FIR and IIR filters can be set in order to obtain the transient response and a stable measurement signal. To filter out unwanted periodic interference frequencies, up to four stages of comb filters and/or moving average filters can also be added.

Two limit value switches

The limit value switches are programmed according to the specifications of the IO-Link Smart Sensor Profile. In addition to the threshold value, you can define a hysteresis if your process requires this. The so-called 'window mode' is also available. Here, a limit switch is activated when the measured value is within a range defined by you, for example between 1 kg and 1.8 kg.

Both switches can be negated.

Application-specific process algorithms

HBK IO-Link load cells offer integrated checkweighing and filling algorithms.

The filler algorithm allows for process control of simple and complex filling processes. The algorithm optimises and controls the coarse flow and fine flow timings as well as fine flow lockout time and the residual flow time. With this algorithm the IO-Link load cell functions as decentralised process controller, realising efficient and highly optimised filler applications.

The checkweighing algorithm allows for optimised and fast measurements of all common industrial checkweighing applications. Pre-Triggering and Post-Triggering can be set and externally communicated to the load cell via IO-Link. Paired with an optimised filter setting, fast and highly accurate measurements are possible.

One fixed digital switching output, one configurable switching output

A single digital output is always available so that results can be obtained quickly at the digital switching output.

You can deactivate the transmission of IO-Link communication and activate SIO mode. The line that has become free now functions as a second digital output. Both distributed input/output systems (DIOs) can be used for process control of the integrated filler and checkweigher algorithms and limit switches.

Sensor health monitoring: warning in the event of critical operating states (static and dynamic overloads, temperatures outside the specification)

During production, all essential sensor properties are stored in the amplifier module:

Highest operating temperature/lowest operating temperature
Limit temperature electronics
Processor limit temperatures
Highest rated load/lowest rated load
Maximum operating load/minimum operating load
Highest rated temperature/lowest rated temperature
Maximum peak-peak value (amplitude)

The electronics constantly compare the load values with the limits and report any overruns so that appropriate action can be taken.

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IO-Link Sensors help you digitalise industrial processes

How does IO-Link work?

IO-Link technology marks a new era for sensors in mechanical applications, enhancing accuracy, reliability and efficiency – all while lowering your business costs

Learn how IO-Link smart sensors can help you reduce costs, improve efficiency and achieve your business goals

White paper: Enhance your efficiency with strain gauge-based smart sensors empowered by IO-Link interface

Easy, cost-efficient integration into your existing infrastructure