Wireless IO-Link is ‘easiest way’ to make sensors and actuators cable-free
12 February 2025 
The German sensor-maker Sick has announced an IO-Link wireless gateway that, it says, is the easiest way to make sensors and actuators wireless. It adds that the gateway will cut installation costs, and provide real-time data streaming to enterprise and cloud platforms for advanced analytics and predictive maintenance, without needing costly cabling.
The bidirectional gateway, which supports multiple sensors, is said to be ideal for applications where wired connections are impractical or impossible. It will allow machine designs that were not previously possible, and can be retrofitted easily to existing installations to provide flexibility, future-proofing and scalability.
The IP67-protected gateway consists of three main elements: an IO-Link master acting as a central controller, a hub with four IO-Link ports, and a bridge that extends communications to applications that need mobile accessibility over longer distances. The bridge and the hub feed data to the master, which can support up to 16 sensors. The gateway can provide smart connections over distances of up to 20m, with a latency of 5ms.
Plug-and-play operation simplifies installation and eliminates the need for programming or complex wiring. Sensors can be configured remotely via the gateway. To ensure uninterrupted data transmission and accurate data collection, the wireless network uses dynamic frequency hopping and blacklisting techniques. Local power cabinets reduce interference, voltage drops and electrical noise, to safeguard data accuracy.
The point-to-point wireless communication system adapts to any existing data infrastructure. Using the Connect X platform, it can provide access to various IIoT interfaces, including Rest API and MQTT, as well as fieldbuses including Profinet, EtherNet/IP and EtherCat.
Sick offers several examples of how the wireless gateway could be used, including:
- helping food and beverage manufacturers to maintain strict hygiene standards by eliminating cabling, which can harbour bacteria and cause cross-contamination;
- providing rapid, cost-effective scalability for conveyors and cross belt-sorters by supporting more sensors over longer distances, allowing additional sorting stations and extensions without costly hardware upgrades; and
- enabling real-time, cable-free communications with transport systems such AMRs, AGVs and forklifts, with low latency and high data integrity.
