Connected safety: the rise of IO-Link Safety interlocks

The last few months have seen rising interest in IO-Link Safety. Building on the strengths of IO-Link - a standardised, point-to-point communication protocol that connects sensors and actuators to control systems - IO-Link Safety adds a safety communication layer, allowing the incorporation of safety devices such as interlocks.

There are several advantages from using safety devices such as interlocks on IO-Link Safety, especially for those organisations looking to modernise and simplify their safety architecture:

Easier Integration - Interlocks like tGard can communicate directly with the IO-Link Safety master. This eliminates the need for hardwiring individual safety relays or relying solely on conventional fieldbus systems.

Enhanced Diagnostic Data - Users can monitor device performance, assess operating times, identify fault trends, and act before failures occur. This improves uptime and supports predictive maintenance strategies.

Plug-and-Play Device Replacement - If a unit needs to be replaced, the system recognises the new device and restores the previous configuration, with minimal downtime.

Reduced Cabling and Installation Costs - Devices are engineered with a 5-pin M12 connector for both power and data. This reduces cabling complexity, cuts installation time, and saves costs, especially on larger systems where wiring traditionally adds up quickly.

Developing an IO-Link Safety interlock

Fortress has received both conformance and functional safety certification for an IO-Link Safety device from TUV SUD. In a recent interview, Fortress experts discussed what this means for customers, the development journey, and which industries stand to benefit the most.

The company has worked closely with technology partners and industry groups throughout the process to ensure our products are reliable, interoperable, and ready for the market.

Who benefits the most from IO-Link Safety?

This safety data communication technology is ideal for any facility where safety, uptime, and operational insights are crucial. With a 20-metre point-to-point radius, IO-Link Safety allows multiple safety devices to connect to a single safety master.

This kind of scalability makes it particularly effective for automated lines or distributed manufacturing cells. Sectors that demand high configurability, rapid changeovers, and minimal disruption are the ones where this communication protocol provides clear advantages.

With smarter integration, real-time data access, and simplified system maintenance, Fortress is helping enhance safety while enabling greater operational efficiency. The integration of IO-Link Safety into the tGard range marks a significant step forward and positions the company as a leader in delivering future-ready solutions to support the customers' digital transformation goals.