Trim Design Space and Upgrade Industrial Efficiency with Two IO-Link Reference Designs

Maxim Integrated integrates the benefits of IO-Link into a proximity sensor and a 16-channel digital-input hub.

San Jose, CA—August 18, 2014—Two new subsystem reference designs from Maxim Integrated Products, Inc. (NASDAQ: MXIM) provide very accurate, low-power optical proximity sensing (MAXREFDES27#) and enhance distributed control with a compact digital-input hub (MAXREFDES36#).

Modern “smart” manufacturing relies heavily on high-speed automation and superior sensing. With that comes an increased need for versatile and accurate proximity sensing—never an easy task—and more system sensor inputs. Both of these new space-saving subsystems integrate the IO-Link® standard for industrial applications. The MAXREFDES27# proximity sensor employs the IO-Link protocol to provide efficient two-way communication between a controller and a remote optical sensor. The MAXREFDES36# digital hub utilizes the IO-Link protocol to enhance distributed control, enabling 16 digital inputs to reside near binary sensors, thereby reducing expensive and bulky cabling at the PLC side and enabling higher DI density.

MAXREFDES27# Proximity Sensor
The MAXREFDES27# IO-Link subsystem reference design lets operators tune and calibrate an optical proximity sensor with excellent accuracy, up to 14 bit resolution. Integrated DC-DC low-power conversion increases system efficiency. The design is tunable and can be calibrated for different surfaces and light levels.

Highly integrated: board integrates the DC-DC converter, an IO-Link transceiver, the proximity sensor, and a Renesas RL78 microcontroller for improved efficiency, reliability, and system configurability.
    
Ultra-low power: consumes only 150mW (typ); the lower power reduces heat dissipation, resulting in higher reliability and increased uptime.
    
Robust IO-Link performance: provides self-configuration, efficient two-way communication between sensor and control module, and several protection mechanisms.

Tiny form factor: entire design fits on an 8.2mm x 31.5mm printed circuit board (PCB).

MAXREFDES36# 16-Channel Digital Hub
Industrial control typically has a rat's nest of input wires running from various sensors to the digital-input module of the programmable logic controller (PLC). This conventional setup is difficult to troubleshoot and expensive to maintain. The new MAXREFDES36# IO-Link subsystem merges 16 of these digital inputs into its hub and eliminates 15 cables connected to the PLC. It consumes only 235mW of power and is 60% smaller than current solutions. This space-saving digital hub lets manufacturers fit more digital inputs into each system controller. It simplifies operation complexity, reduces maintenance costs, stabilizes low-power consumption, and increases uptime.

High integration: DC-DC power converter, two 8-channel digital-input serializers, an IO-Link transceiver, and a Renesas RL78 microcontroller on one board.

Robust IO-link performance: provides self-configuration, short-circuit and shutdown protection, thermal warnings, and drive capability.

Low power: consumes only 235mW (typ).
Small size: 53.75mm x 72mm, fits in a standard DIN rail PCB holder and is 60% smaller than current solutions.

Commentary
“Proximity sensing and distributed control are two critical elements of the industrial transformation. Utilizing IO-Link with an optical sensor makes for a low-power, versatile sensor. By reducing the number of wires running across the factory floor, the digital-input module lowers cable cost and simplifies maintenance,” said Reference Design Manager David Andeen. “The MAXREFDES27# and MAXREFDES36# enable customers to create better industrial designs quickly, reduce cost, and improve the overall factory performance.” 

Pricing
Pricing for MAXREFDES27# and MAXREFDES36# boards are $99 each. The schematics, layout files, and firmware (including IODD files for IO-Link) are free and available for immediate use.

For information on other reference designs, please visit Maxim's Reference Design Center. 

About Maxim Integrated

Maxim is the leader in analog integration. From mobile to industrial solutions, we're making analog smaller, smarter, and more energy efficient. Learn more at www.maximintegrated.com.