In the development of automated testing equipment, harsh on-site environments and widely dispersed I/O points have long posed significant challenges for electrical design. Traditional in-cabinet I/O solutions often require the installation of numerous multi-core cables and the addition of local control cabinets—increasing both the equipment's physical footprint and material costs, while also complicating long-term maintenance. This case study explores the application of the WAGO IP67 Field BaseLine IO-Link series in wheel and tire testing equipment.
The client, a Tianjin-based company, specializes in the R&D and manufacturing of performance testing equipment for wheels and tires. Their systems are primarily used for long-duration, cyclic testing—evaluating factors such as tire strength, durability, and dynamic performance—and are controlled by an EtherCAT-based PLC system. Given the large number of workstations and the fact that sensors and actuators are distributed throughout the machinery—combined with a factory environment prone to dust and oil—the client sought to achieve a more compact equipment design by eliminating the need for traditional control cabinets.
The WAGO IP67 I/O SYSTEM BaseLine Solution
For this project, the client opted for the WAGO IP67 Field BaseLine IO-Link "one-stop" master/slave solution. The modules can be mounted directly onto the equipment frame, removing the need for additional on-site control cabinets.
8-Port IO-Link Master (Product Model: 8000-099/000-5656)
The WAGO IP67 I/O SYSTEM BaseLine IO-Link Master (model 8000-099/000-5656) features a rugged metal housing and supports an operating temperature range of -20°C to +80°C, making it ideal for equipment that requires continuous, long-term operation. It provides eight IO-Link ports and supports the EtherCAT protocol, allowing for seamless integration with the existing PLC. Furthermore, the module includes built-in LED status indicators for the fieldbus, power supply, and individual channels, which simplifies on-site commissioning and troubleshooting. 16-Channel Digital I/O IO-Link Slave (Part No. 8000-099/000-5522)
The WAGO IP67 I/O SYSTEM BaseLine IO-Link slave (Part No. 8000-099/000-5522)
Features an IP67 protection rating, allowing for decentralized installation directly at individual inspection stations. Its 16 digital input/output (DI/DO) channels are software-configurable and equipped with overvoltage and short-circuit protection to safeguard field sensor circuits.
Key Benefits for Customers
1. IP67 High-Level Protection: Cabinet-Free Installation
Both master and slave modules meet the IP67 standard, offering resistance against dust and oil, and can be mounted directly onto the equipment frame.
2. Two-Tier IO-Link Expansion: Ideal for Modular Equipment Design
With two-tier expansion capabilities, a single master can support up to 256 digital I/O channels. When changing test tooling, additional slave modules can simply be added without requiring significant modifications to the PLC program architecture.
3. End-to-End Digital Diagnostics: Reduced Downtime and Maintenance Costs
Leveraging bidirectional IO-Link communication, the system enables a continuous data flow from the controller to the sensors. Information regarding short circuits, power supply anomalies, or bus faults is transmitted to the PLC, allowing maintenance personnel to quickly pinpoint the source of a fault—eliminating the need to manually check individual cables.
4. Comprehensive Certifications
Fully certified with CE and UL, meeting both domestic acceptance standards and requirements for equipment export.
The WAGO IP67 Field BaseLine IO-Link master/slave solution is specifically designed to address the challenges of tire inspection equipment, including harsh operating environments, geographically dispersed measurement points, and frequently changing tooling. It supports cabinet-free, on-site installation; offers flexible IO-Link expansion for modular designs; simplifies operations and maintenance through digital diagnostics; and is compatible with EtherCAT for stable data acquisition. This helps equipment manufacturers strike an optimal balance between performance, cost, and delivery efficiency.
Post time: Oct-16-2026