Drives and Control Solutions

Motors, Control Solutions, Power Transmission and Advanced Motion Technology                                                                 

January 11, 2022

DCS PepperlFuchs Condition Monitoring w IO Link Rotary Encoders 1 400


Whether in the material handling industry, in packaging machines, or in wind turbines—sensors with IO-Link interface are increasingly being used to pave the way to Industry 4.0. With the ENA**TL-**IO-Link, Pepperl+Fuchs was one of the first manufacturers to launch an absolute rotary encoder with IO-Link interface, which is available in numerous variants and with a wide range of setting parameters. Pepperl+Fuchs explain how you can benefit from easy configuration and integration with this IO-Link rotary encoder, while at the same time monitoring the status of your plants in a cost-effective manner.

Why Rotary Encoders with IO-Link?

The internationally standardized IO-Link interface enables continuous communication between the control level and the individual sensors at the field level. Sensors equipped with IO-Link not only fulfill their actual sensor function, but also create the basis for systematic diagnostic concepts. Therefore, the condition of machines can be continuously monitored so that failures and downtimes can be prevented through predictive maintenance.

The use of intelligent, communication-capable rotary encoders is an easy way to implement condition monitoring and predictive maintenance: this way, no high investments are required for retrofitting the plant. Since other sensor technology, for example in material handling technology, is also increasingly being converted to IO-Link, the IO-Link rotary encoder fits seamlessly into the overall concept of many industrial plants. Furthermore, the measured values are transmitted at a speed of 230.4 kBit/s via COM3—the highest transmission speed in the IO-Link standard.

Sophisticated Functionalities

Pepperl+Fuchs offers a wide range of IO-Link rotary encoders in different mechanical variants that can be implemented in all common applications for absolute rotary encoders. Due the magnetic detection principle, the sensors are robust and wear-free, and precisely detect the rotation angle of the encoder shaft. In addition, the ENA**TL-**IO-Link comes with a multitude of sophisticated functionalities:

  • The multiturn function enables the mapping of cyclic applications.
  • The preset function allows position values to be adjusted during operation. This way, inaccuracies caused by slip can be compensated for without the need for time-consuming readjustment.
  • The rotary encoder not only measures position values in rotating movements, but also temperature values. This makes it possible to draw conclusions about the condition of the machine.
  • Critical position and temperature ranges—so-called signal flags—can be individually defined. As soon as a critical value is reached, the machine can be switched off automatically.

Easy Commissioning Due to IO-Link

DCS PepperlFuchs Condition Monitoring w IO Link Rotary Encoders 2 400

The IO-Link interface not only enables condition monitoring and predictive maintenance, but also facilitates configuration and integration of the rotary encoder. Via an IO-Link master, the ENA**TL-**IO-Link can be parameterized more quickly and easily than conventional rotary encoders. The IO-Link master offers extensive configuration options: the parameters can be easily adapted via software tools. On request, the rotary encoders can also be delivered with customer-specific parameter adaptation, even in small quantities.
Our customers also benefit from the advantages of the IO-Link interface when replacing the sensors: Since the setting parameters are stored both in the rotary encoder and in the IO-Link master, there is no need for time-consuming re-parameterization. This saves time when replacing sensors in existing systems.

Three Practical Application Examples

Typical applications for the ENA**TL-**IO-Link are positioning and length measurement tasks, for example on conveyor belts, cranes, elevators, and packaging machines. In the following, you will learn more about three practical application examples.

On Conveyor Belts

IO-Link sensor technology is already widely used in conveyor technology. Therefore, the IO-Link rotary encoder fits perfectly into the overall architecture of existing plants: Since all components are based on the same standard and can be commissioned in a similar way, the management and maintenance effort is reduced.
For example, the ENA**TL-**IO-Link is used on conveyor belts in beverage filling machines. Depending on the type of bottle, the width of the conveyor belt must be flexibly adjusted so that the bottles run in an accurate row for filling and labeling. Attached to an automatic crank wheel, the IO-Link rotary encoder uses the adjustable signal flags to provide information on whether the new conveyor belt width has been correctly implemented by the motor.

In Wind Turbines

Due to its robust design, the ENA**TL-**IO-Link is also suitable for use in harsh environments—for example, in wind turbines. Here, it detects the position of the nacelle as part of the azimuth control to determine whether the alignment to the wind has taken place correctly. At the same time, it measures how often the nacelle has already been turned in which direction. This makes it possible to decide whether the turbine must be turned to the left or to the right in order to prevent a cable break between the nacelle and the tower. With its painted and galvanized housing, a flange made of aluminum and an encoder shaft made of V2A stainless steel, the sensor is protected against corrosion. In accordance with the degrees of protection IP65 and IP67 (extra charge), it is also insensitive to splash water and temporary submersion. Therefore, the rotary encoder can easily handle weather conditions like rain or snow.

On Ship Cranes

Due to its high resistance, the ENA**TL-**IO-Link is also suitable for offshore environments: The mechanical parts of the sensor are protected against the effects of salt and the associated risk of corrosion, as well as against splash water and temporary submersion. In cranes that are used for loading and unloading on ships, the rotary encoder can be employed to monitor the horizontal and vertical movement of the machine. Since the rotary encoder is installed inside the equipment, its inherent protective measures are sufficient so that a heavy-duty rotary encoder is not necessary.

DCS PepperlFuchs Condition Monitoring w IO Link Rotary Encoders 3 400

Additional Information

Interested in using the ENA**TL-**IO-Link in your plant? Experts at Pepperl+Fuchs look forward to your inquiry, and will be happy to support you in making the best choice.

Learn more here:

Product Selection ENA**TL-**IO-Link rotary encoder

More about sensors and systems with IO-Link

The complete portfolio of rotary encoders by Pepperl+Fuchs


Editor's Pick: Featured Article

DCS HELUKABEL Critical Keys to Selecting Right Cable Manufacturer 1 400

As we began 2022, global material shortages and rapidly increasing costs have now become the new reality. The types of materials that have suddenly become difficult to procure are wide-ranging and include computer chips for automotive manufacturing, wood for new construction, and electrical components – just to name a few.

These shortages have created great uncertainty, which is reflected in a recent poll of contractors in the U.S. by the Chamber of Commerce. They reported:

  • •83% are experiencing product delays.
  • •71% are struggling to meet schedule requirements.
  • •68% are experiencing delays expected into 2023.
  • •58% are putting in higher bids on projects.
  • •53% are saying major project shutdowns/delays are a top concern.
  • •41% are saying material shortages continue.
  • •39% are turning down work opportunities.

One of the major material components that affect the cost and availability of wire and cable is copper. This widely used metal, which traditionally has been a volatile commodity, has been steadily increasing in price, which is due to several supply and demand issues.

Read more



Motors for RoboticsTradeoff 1: Torque Density vs. Size 

When calculating the torque requirements for robotic joints, you may run into the first tradeoff: How can you increase the torque in a robotic motor without increasing its size? 

In the frameless motors used in robotic joints, torque increases in direct proportion to an increase in motor length, or as the square of an increase in diameter. In other words, doubling the diameter produces a fourfold increase in torque, known as the D2L rule. In order to achieve the torque required to move and hold substantial loads, the most common approach is to use a larger-diameter robotics motor rather than a longer one, which would make the joint too large and difficult to integrate into your overall design. 

Read More



Hydrogen EnginesHydrogen is an increasingly popular energy carrier. It can be readily produced from water using renewable electricity, and it burns without any greenhouse gas emissions. It is colorless, odorless, and does not spill. It’s no wonder there is a great interest in hydrogen engines as a part of destination zero. 

In this article, Cummins explains how hydrogen fuel can power a vehicle by comparing the similarities and differences between hydrogen and diesel and gas engines and provides some examples of hydrogen engines in mobility and transport. 



Read More


Product News

  • Prev
  AutomationDirect has added drive isolation transformers from Hammond Power Solutions ...
  The new SPS30 AC/DC In-Line Power Converter is a compact, cost-effective device that ...
  At less than 25mm length (+ lead-wires) and 13mm diameter our new pressure sensor ...
  Mersen is pleased to announce non-indicating versions of its popular A2D and A6D ...
  Littelfuse Inc., an industrial technology manufacturing company empowering a ...
  AutomationDirect has added additional safety mats, edges, and bumpers from ASO Safety ...
  Festo’s new manually adjustable VFOE meets all the criteria users are seeking in a ...
  Recently, Emerson introduced the TopWorxTM DX PST with HART® 7. Units provide ...
  Franklin Electric Co., Inc.brand Pioneer Pump® announces the launch of the ...
  Optical sensors detect an object by emitting light beams, which ...

New Product

Augmented Intelligence Platform for Oil and GasEZ Ops, the provider of oil and gas operations software that identifies top priorities to produce the cleanest and most profitable hydrocarbons in the world, has announced the second release of its augmented intelligence operations platform with new capabilities for dynamic routing and day scheduling. 

EZ Ops latest platform release helps operators efficiently plan their daily schedule in under three minutes with certainty they are doing highest value work during their shift, with the least drive time and lowest greenhouse gas emissions. Intelligent schedules and routing draw on algorithms that compute millions of internal and external data including production data, inspection schedules...

Read More


Latest News

  • Prev
  The ABB #BuildtheFuture Roadshow delivers the latest electrical products, services, ...
  Global industry is accelerating its investment in energy efficiency in the next five ...
  In March 2022, the new edition of the installation standard IEC 61918:2018/AMD1:2022 ...
  On this episode of the Allied Expert Advice podcast, Carlos Riano, Senior Offer ...
  Advanced Micro Controls Inc. (AMCI) has realized growth throughout the Midwest United ...
  Ballard Power Systems recently announced that the company has launched a three-year ...
  Discover the difference a Gutor-backed setup can have on your business and ...
  Control Techniques Engineers step up to the plate, in record time, to tackle the ...
  ABB Ability™ Smart Melt Shop digitally connects all steel melt shop processes ...
  Following the announcement made by Bavarian Prime Minister Dr. Markus Söder in the ...
Kerrwil Publications Great Place to Work. Certified December 2019 - December 2020

538 Elizabeth Street, Midland,Ontario, Canada L4R2A3 +1 705 527 7666
©2022 All rights reserved

Use of this Site constitutes acceptance of our Privacy Policy (effective 1.1.2016)
The material on this site may not be reproduced, distributed, transmitted, cached or otherwise used, except with the prior written permission of Kerrwil