Smart flow measurement: Unlocking efficiency with IO-Link technology

Do you know that flow measurement is one of the oldest known measurement techniques, dating back to ancient, early civilisations?

Picomag flowmeter integrated with IO-Link

Many ancient navigators gathered information about the direction and velocity of airflow. Many early communities, such as the Sumerian cities of Ur, Kish, and Mari near the Tigris and Euphrates Rivers around 800 B.C., used to measure water flow for the fair distribution of water through the aqueducts.

Today, accurate flow measurement is essential for efficient, safe, and compliant operations in various industries such as food and beverage, pharmaceuticals, water treatment, and chemicals. Flowmeters drive process reliability and product quality, from ensuring accurate dosing in beverage production to monitoring wastewater flows. However, traditional flow measurement encounters challenges like complex installations, limited real-time data, maintenance downtime, and integration hurdles with modern automation systems. These challenges can lead to inefficiencies, increased costs, and operational risks.

What if you could see directly into your process?

The latest Innovations in magnetic flow meters with IO-Link technology offer a game-changing solution that transforms flowmeters into smart, connected devices. This blog discusses the IO-link-enabled flowmeters, which provide seamless digital communication and offer enhanced accuracy, simplified integration, and predictive maintenance, eliminating any guesswork.

The power of IO-link in flow measurement

IO-Link is a standardised digital communication protocol (defined by IEC 61131-9) that connects sensors and actuators to automation systems. It enables bidirectional data exchange and delivers real-time process data, diagnostics, and configuration capabilities, surpassing analog systems that rely on 4–20 mA signals. IO-Link technology simplifies the digitalisation of field devices with communication protocols like Profinet, Profibus, Modbus, and Ethernet/IP. It reduces cabling complexity and ensures plug-and-produce functionality. IO-Link-based flowmeters provide precise measurements, remote parameterisation, and advanced diagnostics, thereby minimising downtime and boosting efficiency. One such example is Endress+Hauser's Picomag electromagnetic flowmeter with a compact design and Industry 4.0 ready for hygienic and industrial applications.

Figure 1: Picomag flowmeter integrated with IO-Link

Addressing industrial flow measurement challenges with IO-Link

Traditional flowmeters often struggle with challenges like inaccurate readings due to environmental factors, time-consuming, complex configurations, and maintenance delays. IO-Link tackles these issues directly:

Simplified Installation: IO-Link flowmeters, like the Picomag, come in nominal diameters ranging from DN15 to 50 (1/2 to 2"), making them perfect for skid-mounted installations. Quick offline configuration reduces commissioning time.
Enhanced Data Access: IO-Link provides real-time insights into flow rates, flow direction, units, and diagnostics messages, enabling proactive decision-making. Operators can monitor performance remotely via the Bluetooth SmartBlue app, ensuring optimal process control even in hard-to-reach areas.
Predictive Maintenance: With features like Endress+Hauser's Heartbeat Technology, IO-Link flowmeters offer in-depth diagnostics and verification, minimising unexpected failures and calibration needs.
Cost Efficiency and Rugged Performance: Picomag IO-Link flowmeters come with IP65/67 ratings and are highly resistant to shock and vibration. Their scalable design and reduced wiring requirements make them a cost-effective solution for industries by minimising wiring and maintenance costs.

Widespread applications of IO-Link flowmeters

IO-Link flowmeters are versatile and support various industries, including food and beverage, pharmaceuticals, water and wastewater treatment, and chemical processing. A notable example is a European beverage manufacturer that faced challenges with inconsistent flow measurements in a high-speed bottling line, leading to overfilling and waste. Their traditional flowmeters required frequent manual calibration, increasing the downtime.

By adopting Endress+Hauser’s IO-Link-enabled Picomag, the plant transformed its operations. The Picomag’s IO-Link interface allowed remote configuration via the SmartBlue app, reducing setup time by 30%. Endress+Hauser's Heartbeat Technology provided real-time diagnostics, reducing maintenance costs by 15% . The result? A 20% increase in production efficiency, reduced material waste, and compliance with hygienic standards, showcasing the power of IO-Link in real-world applications.

What if you could see directly into your process with the latest innovations in magnetic flow meters and IO-Link technology? Whether in food production, pharmaceuticals, or wastewater management, these smart devices, available through Farnell, deliver unmatched reliability and Industry 4.0 compatibility.

Ready to transform your flow measurement? Explore our range of flowmeters and elevate your operations today.