IO-Link Wireless is revolutionizing rotary unit design by eliminating traditional constraints like large slip rings and excess cabling.
In manufacturing plants, rotary tables and carousels are essential components. They can facilitate the movement, positioning, and processing of parts or products.
Common uses for rotary tables include:
- Machining and Precision Work – Ensuring accurate positioning and rotation for cutting, drilling, and milling.
- Assembly Automation – Enhancing efficiency in automated assembly lines.
- Inspection and Testing – Supporting precise quality control and measurement processes.
- Welding and Painting – Allowing uniform and controlled application of materials.
Carousels, often designed as continuous or indexed rotating conveyors, move products or parts in a circular or looping path. They serve several roles in manufacturing, such as material handling, parts storage and retrieval, kitting and sorting, and packaging and filling.
Key Takeaways
- Traditional rotary units rely on slip rings and wired connections, leading to size constraints, mechanical wear, and high maintenance costs.
- IO-Link Wireless eliminates large slip rings and cables, allowing real-time, industrial-grade communication for sensors and actuators on rotating components.
- Manufacturers benefit from lower costs, increased flexibility, and simplified deployment, making retrofitting and upgrades easier.
- Wireless technology future-proofs manufacturing, enabling seamless integration with Industry 4.0.
- The shift to wireless rotary units is transforming production processes, offering manufacturers a competitive edge with smarter and more adaptable automation.
Advantages of Traditional Rotary Units
Rotary tables and carousels in manufacturing have several benefits, such as increased efficiency, space optimization, and automation flexibility. These devices are crucial for achieving continuous, automated production flows in modern manufacturing plants. They help improve precision, throughput, and overall efficiency.
Challenges in Traditional Rotary Units
Despite their advantages, rotary units in manufacturing face several challenges:
-
Reliance on Slip Rings – Traditional systems use slip rings for communication, but space limitations arise when additional lines are needed for upgrades or retrofitting.
-
Size and Cost Issues – Large slip rings can be bulky, expensive, and unsuitable for certain applications.
-
Mechanical Wear and Maintenance – Cabled solutions on high-speed rotating units experience wear, leading to increased maintenance costs.
-
Limited Sensor Integration – Standard wired sensors often fail to provide the extensive data required for advanced analytics.
-
Installation and Downtime – Deploying large slip rings requires significant machine downtime for installation and maintenance.
-
Flexibility Constraints – Cables limit adaptability, making it difficult to adjust to changing manufacturing needs.
All these challenges can be overcome by innovative solutions that allow wireless sensor communication.
Wireless Connectivity: A Game-Changer for Rotary Units
A wireless solution that is designed specifically for the control and monitoring on high-speed moving and rotating components in industrial settings is enabling manufacturers and machine builders to overcome the above-mentioned challenges.
One can easily add connectivity to rapidly rotating devices on rotary tables and carousels, with an industrial-grade wireless, real-time communication solution such as IO-Link Wireless.
With no need for unnecessary cables or slip rings, you can add industrial wireless sensors (e.g. load cell, volumetric sensor) and actuators (e.g. valve, servo motor, gripper) on dynamically rotating machine components such as rotary tables and carousels. Products are processed in the most flexible manner while in constant motion, without manual changeovers, while reducing maintenance and deployment efforts.
Key Advantages of IO-Link Wireless
- At least 30% more cost-effective than traditional wired rotary solutions.
- Simplified deployment and management with no cables between the master and sensors/actuators.
- Easier retrofitting for additional units as needed.
- Increased system flexibility for evolving production demands.
Real-World Applications of IO-Link Wireless for Rotary Units
These case studies reflect the successful use of IO-Link Wireless for rotary units:
Case Study #1: Wireless Technology Boosts Flexibility and Efficiency
Company: Pedrini – A leader in natural stone processing machines.
The Challenge:
- Needed to integrate multiple analog sensors into rotary units without redesigning existing machines.
- Traditional communication cables complicated deployment.
The Solution:
- Integrated IO-Link Wireless to upgrade the SPECTRA B220 stone grinding machine.
- Used IO-Link Wireless Bridges (TigoBridge) connected to multiport I/O hubs to connect 24 analog sensors wirelessly per each rotary head.
- A single IO-Link Wireless Master (TigoMaster) wirelessly communicates with all the sensors and seamlessly transfers the data to the PLC for real-time calibration and optimization.
The Results:
- Reduced slip ring complexity, cutting costs and deployment time.
- Easier retrofitting without cabling constraints.
- Lower maintenance costs with fewer spare parts needed.
- Improved reliability in harsh industrial environments.
Case Study #2: IO-Link Wireless Reduces Complexity and Maintenance
Company: Siboni – A provider of motor solutions for automated bottle rotation in packaging machines.
The Challenge:
- Required real-time control of servo motors on rotary tables and carousels.
- Needed to minimize cable connections for increased flexibility.
The Solution:
- Implemented wirelessly controlled electric servo motors with IO-Link Wireless.
- The motors communicated over the air via the IO-Link Wireless Master, rotating bottle labels for proper orientation.
The Results:
- Minimal cable requirements (only a single power cable runs through the center axis/slip ring)
- Reduced deployment time and maintenance.
- Lower payload and increased efficiency.
Case Study #3: Rotary Table Retrofit for Tool Manufacturing
Company: Global Tool Manufacturer
The Challenge:
- A manufacturer needed to control multiple grippers on a rotary table on a tool production line.
- Pneumatic setups suffered from mechanical wear and lacked data collection capabilities.
- Slip rings were expensive, large, and added payload.
The Solution:
- Replaced wired pneumatic setup with IO-Link Wireless for gripper control.
- Enabled comprehensive data collection while eliminating slip ring limitations.
The Results:
- Simpler deployment with no need for large slip rings.
- More cost-effective and easier maintenance than wired alternatives.
- Enhanced monitoring and calibration capabilities for production efficiency.
The Significant Impact of IO-Link Wireless on Rotary Units
IO-Link Wireless is revolutionizing rotary unit design by eliminating traditional constraints like large slip rings and excess cabling. With benefits such as increased flexibility, reduced costs, and simplified deployment, manufacturers can optimize their production processes while future-proofing their operations.
As companies like Pedrini and Siboni demonstrate, wireless solutions not only enhance efficiency but also enable seamless integration into Industry 4.0 environments. They are a new game-changer for modern manufacturing.
