Smart Factory: IO-Link Sensor/Actuator
Smart factory sensors and actuators facilitate better decision making to support flexible and readily optimized manufacturing processes. Analog Devices, Inc. (ADI)’s IO-Link® technology transforms traditional sensors into smart sensors to upgrade industrial facilities into real-time configurable smart factory floors. ADI’s IO-Link controller and device transceiver portfolio offers a powerful and flexible means of moving intelligence from the PLC closer to the sensors and actuators on the factory floor. In tandem with IO-Link, ADI’s high-precision analog converter, linear, and signal conditioning portfolio offers products to match all the performance, power, cost, and size requirements for smart sensor analog front ends.
Embrace the Digital Enterprise with Smart Factory Sensors
ADI’s IO-Link technology removes the need to retrofit new sensor technology to achieve a real-time configurable factory floor. By repurposing traditional sensors into intelligent ones, manufacturers can streamline the manufacturing process with new efficiencies like remote configuration, communication, and real-time sensor diagnostics. Explore ADI’s smart factory sensor solutions.
Overcoming the Power vs. Space Conundrum in Smart Factory Sensors
When designing industrial sensing systems for smart factory applications, power density is a critical challenge. Sensor enclosures are shrinking at the same time that customers are requiring them to deliver more features, and in this context, excessive power dissipation can lead to device failure. ADI’s IO-Link technology can enable sensor intelligence, and careful consideration can help you address the heat challenge when selecting which transceiver to use.
Interactive Signal Chains
The MAX14828 integrates the high-voltage functions commonly found in industrial sensors. The MAX14828 features one ultra low-power driver (C/Q) with active reverse-polarity protection. An auxiliary digital input is provided to allow firmware updates through a UART interface. Transient protection is simplified due to high voltage tolerance allowing the use of micro TVS.
The device features a flexible control interface. Pin-control logic inputs allow for operation with switching sensors that do not use a microcontroller. For sensors that use a microcontroller, an SPI interface is available with extensive diagnostics. For IO-Link operation, a UART interface is provided, allowing interfacing to the microcontroller UART. Finally, a multiplexed UART/SPI option allows using one serial microcontroller interface for shared SPI and UART interfaces.
The device includes on-board 3.3V and 5V linear regulators for low-noise analog/logic supply rails. The MAX14828 is available in a (4mm x 4mm) 24-pin TQFN package and a (2.5mm x 2.5mm) wafer-level package (WLP) and is specified over the extended -40°C to +125°C temperature range.
- Industrial Sensors
- IO-Link Sensors and Actuators
- Safety Applications
The MAX22513 dual-channel low power IO-Link device transceiver features a selectable control interface, internal high-efficiency DC-DC buck regulator, two internal linear regulators, and integrated surge protection for robust communication. The device features low-on resistance drivers (C/Q and DO/DI), selectable driver current limits, and overcurrent protection to reduce power dissipation in small sensor applications.
The DC-DC buck regulator supplies up to 300mA load current and has an adjustable output voltage (from 2.5V to 12V). Internal linear regulators generate 5V and 3.3V, supplying up to 50mA of current.The MAX22513 can be controlled using SPI or I2C interfaces, providing flexibility for microcontrollers, and extensive control and diagnostic features. Both full- and half-duplex SPI are supported. The internal MCLK oscillator provides a clock source to a microcontroller for IO-Link communication.
The MAX22513 features extensive integrated protection to ensure robust communication in harsh industrial environments. All four IO pins (V24, C/Q, DO/DI, and GND), are reverse voltage protected, short circuit protected, and feature integrated ±1kV/500Ω surge protection.
The MAX22513 is available in a tiny WLP package (4.1mm x 2.1mm) or 28-pin TQFN-EP package (3.5mm x 5.5mm) and operates over the -40°C to +125°C temperature range.
- Industrial Sensors
- IO-Link Sensor and Actuator Devices
The MAX22514 IO-Link transceiver integrates high voltage functionality, including one 24V line driver, an integrated DC-DC buck regulator, and 5V and 3.3V linear regulators. The MAX22514 is targeted for IO-Link devices, masters, and industrial switching sensor applications, and can be configured and monitored using a standard SPI interface.
- IO-Link and Industrial Sensor and Actuator Devices
- The MAX22514 features a SPI interface for configuration and diagnostics. A high level of integration (including two linear regulators, a DC-DC buck regulator, and integrated surge protection, combined with low power dissipation and small packages) optimizes the MAX22514 for use in many different industrial and IO-Link small sensor applications.
- IO-Link Master Transceivers: The MAX22514 is capable of being used in both IOLink devices and IO-Link master applications. A SPI interface is used for extended configurability and diagnostics, and the transceiver is capable of operating at the COM1, COM2, and COM3 IO-Link data rates. The MAX22514 can be configured to enable the required 5mA pull-down/pull-up current on the C/Q line and generate a wake-up pulse.
The MAX22515 low-power industrial transceiver can operate as either an IO-Link device or an IO-Link master transceiver in industrial applications. The MAX22515 features a selectable control interface (pin mode or I2C), two integrated linear regulators, and integrated surge protection for robust communication. The transceiver includes one C/Q input-output channel and one digital input (DI) channel.
The device features a flexible control interface. Pin-control logic inputs allow for operation with switching sensors that do not use a microcontroller. For sensors that use a microcontroller, an I2C interface is available providing extensive configuration and diagnostics. Additionally, an integrated oscillator simplifies the clock generation for IO-Link devices.
The MAX22515 features extensive integrated protection to ensure robust communication in harsh industrial environments. All IO-Link line interface pins (V24, C/Q, DI, and GND) are reverse voltage protected, short-circuit protected, hot-plug protected, and feature integrated ±1.2kV/500Ω surge protection.The MAX22515 is available in a tiny WLP package (2.5mm x 2.0mm) or a 24-pin TQFN-EP package (4mm x 4mm) and operates over the -40°C to +125°C temperature range.
- IO-Link Sensor and Actuator Devices
- Industrial Sensors
- IO-Link Masters
The AD4130-8 is an ultra low power, high precision, measurement solution for low bandwidth battery operated applications. The fully integrated analog front end (AFE) includes a multiplexer for up to 16 single-ended or eight differential inputs, programmable gain amplifier (PGA), 24-bit sigma-delta (Σ-Δ) analog-to-digital converter (ADC), on-chip reference and oscillator, selectable filter options, smart sequencer, sensor biasing and excitation options, diagnostics, and newly added features to improve the battery-operated lifetime (more than 5 years on a coin cell), that is, a first in, first out (FIFO) buffer and duty cycling.
The AD4130-8 allows users to measure low frequency signals with a current consumption of 28.5 μA (gain = 1) and 32.5 μA (gain = 128) while continuously converting, and even lower average currents when using one of the duty cycling options. The AD4130-8 can be configured to have 8 differential inputs or 16 single-ended or pseudo differential inputs, which connect to a crosspoint multiplexer, where any input pair can become a measurement channel input to the PGA and ADC.
The AD4130-8 is designed to allow the user to operate from a single analog supply voltage from 1.71 V to 3.6 V. In battery applications, operation as low as 1.71 V can extend the system lifetime as the AFE can continue its operation, even as the battery voltage dissipates. The digital supply can be separate and range from 1.65 V to 3.6 V.
Together with the reduced current consumption, the integration of an on-chip FIFO buffer can be used in tandem with the smart sequencer, to enable the AD4130-8 to become an autonomous measurement system, which allows the microcontroller to sleep for extended periods.
Intelligent interrupt functionality gives the user a greater confidence in both error detection and safety. The user can enable an interrupt signal to trigger when the samples in the FIFO reach a predefined value or when a user programmable threshold is exceeded.
The following key analog functions are offered on the AD4130-8 to allow simple and effective connection to transducers used for measuring temperature, load, and pressure:
- PGA. Due to the programmable gain (from 1 to 128) and the high input impedance with low input current, the PGA allows direct interfacing to transducers with low output amplitudes like resistive bridges, thermocouples, and resistance temperature detectors (RTDs).
- The capacitive PGA allows full common-mode input range, giving designers greater margin for widely varying input common modes. A wider common-mode input range improves the overall resolution and is highly effective in ratio metric measurements.
- Low drift precision current sources. The IEXC0 and IEXC1 current source can be used to excite 2‑, 3‑, and 4‑wire RTDs. Excitation current output options include 100 nA, 10 μA, 20 μA, 50 μA, 100 μA, 150 μA, and 200 μA.
- The low-side power switch (PDSW) can be used to power down bridge sensors between conversions. The PDSW can be controlled within the sequencer on a per channel basis, allowing optimum timing and energy savings in the overall system. The PDSW can also allow higher powered analog sensors to be used in a low power system.
- Voltage bias for thermocouples (the VBIAS source sets the common-mode voltage of a channel to AVDD/2).
- The smart sequencer allows the conversion of each enabled preconfigured channel in a predetermined order, allowing a mix of transducer, system checks and diagnostic measurements to be interleaved. The sequencer eliminates need for repetitive serial interface communication with the device. Sixteen channels can be configured in the sequence, each of them selecting from eight predefined ADC setups that allow selection of gain, filter type, output data rate, buffering, timing, and reference source.
High levels of integrated front-end functionality coupled with small package options allow smaller end solutions. For example, the AD4130-8 integrates a low thermal drift band gap reference in addition to accepting an external differential reference, which can be internally buffered.
In safety critical applications the AD4130-8 includes diagnostic functionality such as open wire detection via burnout currents, internal temperature sensor, reference detection, and analog input overvoltage and undervoltage detection. Added diagnostics are included on the digital interface like cyclic redundancy check (CRC) and serial interface checks for a robust communication link.
- Smart transmitters
- Wireless battery and harvester powered sensor nodes
- Portable instrumentation
- Temperature measurement: thermocouple, RTD, thermistors
- Pressure measurement: bridge transducers
- Healthcare and wearables
Instrumentation & Measurement
The ADA4570 is an anisotropic magnetoresistive (AMR) sensor with integrated signal conditioning amplifiers and analog-to-digital converter (ADC) drivers. The ADA4570 produces two differential analog outputs that indicate the angular position of the surrounding magnetic field.
The ADA4570 consists of two die within one package, an AMR sensor, and a fixed gain instrumentation amplifier. The ADA4570 delivers amplified differential cosine and sine output signals, with respect to the angle, when the magnetic field is rotating in the x-axis and the y-axis (x-y) plane. The output voltage range is ratiometric to the supply voltage.
The sensor contains two Wheatstone bridges, at a relative angle of 45° to one another. A complete rotation of a dipole magnet produces two periods on the sinusoidal outputs. Therefore, the magnetic angle (α) calculated from the SIN and COS differential outputs represents the physical orientation of the magnet with respect to the ADA4570 in the 0° to 180° measurement range. Within a homogeneous field in the x-y plane, the output signals of the ADA4570 are independent of the physical placement in the z direction (air gap).
The ADA4570 is available in an 8-lead SOIC package.
- Absolute position measurement (linear and angle)
- Brushless dc motor control and positioning
- Actuator control and positioning
- Contactless angular measurement and detection
- Magnetic angular position sensing
Precision Medium Bandwidth
The MAXREFDES278# is a complete IO-Link® 8-Channel solenoid actuator reference design based on a MAX22514 IO-Link transceiver with integrated protection. It demonstrates an 8-Channel solenoid actuator using the MAX22200 1A Octal Integrated Serial-Controlled Solenoid Driver with integrated FETs. This reference design has two power-options, it can be powered either through the IO-Link master directly, delivering up to 800mA total load, or for higher currents external power can be provided using an external source. To make sure no current flows back to the IO-Link master, and the IO-Link portion is always powered, this design uses the MAX17608 current limiter with over voltage (OV), under voltage (UV), and reverse protection.
Built in an industrial form factor, and measuring just 85mm x 42mm, the MAXREFDES278# uses an industry-standard M12 connector, allowing a 4-wire IO-Link cable to be used. Each individual solenoid channel has its own 2-way terminal block.
In this design, a STM32 low-power microcontroller interfaces between the MAX22200 octal solenoid driver and the MAX22514 IO-Link device transceiver. The MAX22514 features integrated surge protection for robust communication in a small printed circuit board (PCB) area without requiring external protection components such as transient voltage suppressor (TVS) diodes. The MAX22514 is available in a tiny 25-bump wafer-level package (WLP) as well as a 24-pin TQFN package, allowing the MAXREFDES278# to have a small footprint. The design is reverse-polarity protected using the integrated active reverse-polarity protection of the MAX22514. The MAX22514 has an integrated DC-DC converter as well as two integrated low dropout (LDO) regulators (3.3V and 5.0V). The DC-DC converter is used to generate the 3.3V supply for the microcontroller as well as the MAX22200 logic supply, reducing power-dissipation as well as the number of external components required, saving space and cost. The MAX22514 also features a low on-resistance C/Q driver to reduce power dissipation, allowing this reference design to consume minimal power with very low thermal dissipation.
This IO-Link device utilizes the Technologie Management Gruppe Technologie und Engineering (TMG TE) IO-Link device stack to communicate to any IO-Link version 1.1-compliant master. The board contains a male M12 connector for connecting to a compliant IO-Link master using a standard M12 cable. Connecting the MAXREFDES278# to a USB IO-link master, such as the MAXREFDES165# or MAXREFDES145#, with the associated software allows for easy evaluation.
Design files and software are available on the Design Resources tab. The board is also available for purchase. The reference design document describes the hardware shown above.
- Industrial Automation
- Actuator Modules
- PLC and DCS Systems
- Smart Actuators
The EVAL-AD7124-8SDZ evaluation kit features the AD7124-8 24-bit, low power, low noise analog-to-digital converter (ADC). A 7 V to 9 V external supply is regulated to 3.3 V to supply the AD7124-8 and support all necessary components. The EVAL-AD7124-8SDZ board connects to the USB port of the PC by connection to the EVAL-SDP-CB1Z motherboard.
The EVAL-AD7124-8SDZ software fully configures the AD7124-8 device register functionality and provides dc time domain analysis in the form of waveform graphs, histograms, and associated noise analysis for ADC performance evaluation.
The EVAL-AD7124-8SDZ is an evaluation board that is designed to allow the user to evaluate the features of the ADC. The user PC software executable controls the AD7124-8 over the USB through the system demonstration platform board (EVAL-SDP-CB1Z).
8-Channel, Low Noise, Low Power, 24-Bit, Sigma-Delta ADC with PGA and Reference
The EVAL-AD4130-8WARDZ evaluation kit features the AD4130-8 24-bit, ultra-low power, low noise analog-to-digital converter (ADC).
The EVAL-AD4130-8WARDZ board connects to the USB port of the PC by connecting to the EVAL-SDP-CK1Z motherboard. A 5V USB supply via the PC is regulated to 3.3 V to supply the AD4130-8 and support all necessary components.
The AD4130-8 ACE Plugin fully configures the AD4130-8 device register functionality and provides dc time domain analysis in the form of waveform graphs, histograms, and associated noise analysis for ADC performance evaluation.
The EVAL-AD4130-8WARDZ is an evaluation board that allows the user to evaluate the features of the ADC. The user PC software executable controls the AD4130-8 over the USB through the EVAL-SDP-CK1Z System Demonstration Platform (SDP) board.
- Temperature measurements, such as thermocouple, RTD and thermistors
- Pressure measurement, such as bridge transducers
- Smart transmitters in healthcare and wearables
32 μA, Ultra Low Power, 24-Bit Sigma-Delta ADC with Integrated PGA and FIFO
Precision Narrow Bandwidth
Smart Factory Sensor AFE and Measurement
Industrial smart sensors with IO-Link communication are common across a broad range of measurement modalities such as pressure, temperature, angle, and position. With pre-selected technology combinations, tools, and expertise, ADI’s precision signal chains offer a simplified design journey, with optimizations for key smart sensor performance specifications such as noise, bandwidth, density, and power efficiency. Our analog front end (AFE) sensor signal chains can be quickly evaluated and tuned to exact application needs, with complete LTspice® circuits, technical articles, and power management solutions available for download.
Precision Low Power Signal Chains
ADI's precision low power signal chain platform is adaptable to support multiple sensing modalities, with a rich programmable feature set, all while minimizing power consumption and board space.
ADI’s Complete Precision Signal Chains for Easy System Solutions
Save time and deliver your solutions faster with ADI's precision technology signal chains allowing for ease of navigation between various design trade-offs to create the optimum tailored end-solution.
Learn the Fundamentals of IO-Link Technology
IO-Link is a standardized technology (IEC 61131-9) regulating how sensors and actuators in industrial systems interact with a controller. IO-Link allows for continuous diagnostics, enabling flexible manufacturing to improve factory throughput and operational efficiency.
Redesigning RTD-Based Temperature Sensors for the Smart Factory Age