IO-Link Interface for Smart Sensors

IO-Link enhances production and testing with smart sensors featuring integrated signal processing, real-time diagnostics, and plug-and-play connectivity. Ready for Industry 4.0, they offer performance, flexibility, and greater control.

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IO-Link for Digital Sensor Communication

IO-Link enables smart, connected manufacturing with full data transparency, remote setup, and real-time monitoring—boosting productivity, cutting manual work, and simplifying automation through one flexible, cost-saving three-wire connection.

Integrated data processing and health monitoring reduce costs, boost safety, and cut downtime in your process control.

IO-Link bridges control and field levels, enabling remote diagnostics, faster troubleshooting, and reduced machine downtime.

IO-Link simplifies system design with signal unification and easy PLC integration, thanks to its IEC-based, fieldbus-independent standard.

IO-Link Expert Insights Hub - Power Smart Automation

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Business Gains with IO-Link Smart Sensor
Technical advantages of IO-Link Integration
Choosing the right IO-Link amplifier

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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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IO-Link solutions II white-paper - mockup

Enhance efficiency with strain gauge-based IO-Link interface Smart Sensors

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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Why choose IO-Link sensors with integrated amplifiers?

Integrated IO-Link amplifiers deliver simplicity, accuracy, and cost-efficiency.

By combining sensing, signal processing, and communication into a single unit, these sensors remove the complex, manual setup and the inherent risks of human error associated with stand-alone configurations.

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Webinar Replay: Why Digital Sensors Are the Future – Force, Torque & Load

Explore how IO-Link and digital sensors boost performance, cut downtime, and simplify integration. Don’t miss the tech shaping tomorrow’s automation.

Watch now and transform your processes.

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Smart IO-Link Sensors for Force, Torque & Load Applications

Enhance your automation with HBK’s IO-Link sensors. Precise, connected, and Industry 4.0-ready - for better control, faster integration, and reduced downtime.

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Smart Force Measurement
Smart Torque Measurement
Smart Load Measurement

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Smart Force Sensors – Control Every Newton

For press-fit, joining, or force-controlled processes, HBK’s IO-Link force sensors deliver fast, reliable measurement with 40 kHz sampling, peak detection, and built-in limit alerts.

Get maximum performance, process insight, and integration flexibility — all in one compact solution.

IO-Link Force Sensors

Overview of smart force sensors with IO-Link

Smart Torque Sensors – Precision in Motion

HBK’s IO-Link torque sensors provide dynamic, real-time measurement of torque, speed, angle, and temperature — ideal for test benches, drive systems, and automated assembly.

With integrated power calculation and active limit monitoring, they ensure stability and precision, even at high RPM.

IO-Link Torque Sensors

Optimized for Weighing and Filling

Engineered for high-precision weighing, dosing, and checkweighing, HBK’s IO-Link load cells feature advanced filtering, embedded calibration, and intelligent algorithms.

They guarantee consistent, accurate results with faster commissioning and simplified diagnostics.

IO-Link Load Sensors

Built to Connect - Scalable Architecture with IO-Link

From sensor to system, HBK IO-Link smart sensors offer fast, plug-and-play integration — enabling real-time data, simplified commissioning, and seamless scalability across your automation landscape.

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Smart Sensor - All-in-One Intelligence
System Architecture & Integration

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HBK IO-Link Smart Sensor - All-in-One Intelligence at the Edge

HBK IO-Link smart sensors go beyond measurement. They combine the sensing element, amplifier, signal processing,

IO-Link communication, and built-in application logic in one powerful unit—ready to deliver real-time insights directly from the source.

Strain-Gauge based Sensors with IO-Link Interface – Concept Overview

System Architecture & Integration with IO-Link - Easy to Install. Simple to Scale.

HBK IO-Link sensors seamlessly connect from field level to your IT systems. Our plug-and-play architecture—from sensor to IO-Link Master, and onward via Industrial Ethernet or IIoT protocols—simplifies integration and accelerates deployment.

Whether you’re upgrading existing lines or building new ones, IO-Link makes your automation system smarter, faster, and future-ready.

Strain-Gauge based Sensors with IO-Link Interface – IO-Link Overview

Expert Insights on IO-Link Smart Sensors

Explore this expert-led article series to understand how IO-Link force, torque, and load sensors can simplify integration, boost efficiency, and enhance system control.

Fast-track your sensor technology with HBK IO-Link solution

HBK now offers IO-Link connectivity to its proven range of mechanical sensors in the force, load and torque domains.

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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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