Challenge
A prominent manufacturer of irrigation products aimed to improve the efficiency and reliability of its production line for the irrigation sprinkler heads. The existing system presented significant challenges, such as frequent troubleshooting and extended downtime due to complex wiring methods. Traditional wiring required discrete wires between the control cabinet and machinery, leading to cumbersome installations, increased labor costs, and production delays. Moreover, the customer experienced limitations in their network setup, specifically running out of IP addresses for devices on the factory floor.
Solution
Valin’s involvement in this project began through Valin’s Sun Automation team collaborating with the integrator. The team proposed a retrofit of the production line using IO-Link modules, which offered a streamlined and efficient solution for transmitting digital and analog signals. By leveraging Balluff IO-Link modules, the customer addressed their IP address limitation issue and improved operational efficiency.
The IO-Link solution was implemented across key sections of the assembly line. These modules enabled quicker installation through connectorized sensors and allowed for shorter wire runs, significantly reducing labor and installation time. The new system acted as an electrical barrier between devices and controllers, protecting the PLC’s I/O board from potential damage due to electrical shorts.
The ease of use and flexibility of the IO-Link system convinced the integrator and the irrigation manufacturer to proceed with the solution. The sales cycle was relatively short, as the benefits of IO-Link—such as reduced installation time and enhanced diagnostics—were clear to all stakeholders, and transition with their existing controls platform was seamless.
Customer Benefits
Reduced Downtime: With IO-Link, troubleshooting became faster and less disruptive to the production process. Fewer issues arose during operations, minimizing downtime and keeping the production line running efficiently.
Enhanced Protection: The system’s electrical barriers protected control components, safeguarding the PLC’s I/O board and reducing the risk of costly repairs.
Streamlined Installation: Modular, connectorized sensors made the installation process smoother and faster. By reducing wire counts and utilizing shorter wire runs, the system's integrator was able to cut installation time from two weeks to just four days, resulting in significant labor savings.
Improved Flexibility: The IO-Link system provided more flexibility for future expansions. With the ability to easily integrate additional devices without the need for complex wiring or consuming extra IP addresses, the customer could scale their system as needed.
Long-Term Outlook
Encouraged by the success of the initial IO-Link deployment, the customer plans to expand the use of IO-Link throughout the rest of the production line. The ultimate goal is to outfit every station with network hubs, further reducing downtime caused by sensor or valve failures, enhancing system diagnostics, and achieving even greater operational efficiency.
Although the customer did not perform an official ROI calculation, the long-term benefits of enhanced productivity, reduced labor costs, and minimized equipment damage were clear and substantial. These advantages demonstrate the significant impact of adopting modern automation technologies like IO-Link in improving manufacturing operations.
Conclusion
By implementing IO-Link technology, the manufacturer took significant steps toward improving production efficiency, reducing maintenance costs, and enhancing overall operational reliability. This case study illustrates how modern automation solutions like IO-Link can deliver powerful results, streamlining installation, safeguarding equipment, and supporting the scaling needs of advanced production environments.
Be sure to read our blog: Unlocking Production Efficiency with IO-Link Technology: A Solution for Manufacturers