Distributed IO vs. Remote IO | Differences & Benefits

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How many times have you heard the Remote I/Os and Distributed I/Os interchangeably?
These two I/O systems have some major differences that you should not opt for one instead of the other.
In this video, I’ll clarify this confusion and you’ll learn what Distributed I/Os are and how they differ from Remote IOs. To get some insights about Remote I/Os prior to this video, you can watch our previous video here:
👉 Remote I/Os vs Local I/Os ▶ • Remote I/O System for ...
We can take advantage of Distributed IO systems either by Direct Interfacing with the main PLC, or employing them as a subsystem. We can also use them along with other types of IO configurations like Remote IOs.
Depending on our application and the automation process's features, we can employ them in different parts of our industrial network. Likewise, we can even mix them with conventional parallel wiring and pull some sensor cables directly to the local IO rack within the PLC (Programmable Logic Controller) panel.
In almost all types of communication protocols with Distributed IO configuration, we have more or less the same types of hardware components.
The first and foremost piece of hardware is the network cable. Usually, we can benefit from a two-wire network cable that can transfer both the data or signal and the power at a high speed.
There are:
- Power supplies,
- Repeaters to amplify the signals,
- I/O modules or Hubs for connecting the sensors and actuators,
- Cord sets to connect sensors and actuators to the IO modules,
- Gateway or Controller for transferring the data to the upper level of the automation pyramid.
For a better understanding of the subject, I am going to compare some of the effective properties of Distributed IOs with Remote I/O panels.
Both of these IO systems are utilized at the Actuator/Sensor Level (Field Level) of the Automation Pyramid. At this level, distributed IO systems read the signals and command the actuators via a Bus System or Fieldbus communication network such as AS-interface, IO-Link, Profibus PA, and so on.
Whereas in remote I/O systems, the sensors, and actuators are hardwired directly to the input and output cards and there is no Fieldbus network below them.
On the other side, however, both I/O systems are connected to the same network which is the “Control or Process level” of the Automation Pyramid and the bus protocol would be Industrial Ethernet or a specific Fieldbus protocol like Profibus.
Now, consider a packaging machine as a real-world example to understand some of the Distributed IO features in practice.
This machine is only a part of an extensive industrial process and is usually manufactured by a specific vendor outside of the facilities. Like the rest of the process, we have various sensors and actuators along this machine.
As most of its sensors and actuators are of discrete types, AS interface could be a suitable choice among all available Fieldbus network protocols.
There are multiple benefits to using distributed IO systems, and modularity is one of them.
They have also great hardware options in terms of modularity. The rugged expansion IO module with high levels of ingress protection rating is one of them that has a limited number of input and output connections.
Manufacturers preinstall them outside of the panel and on different parts of the machine, very close to the instruments, and actuators.
Doing so has lots of benefits that I invite you to watch the video to figure out.
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Timestamps of this video:
00:00 Introduction and Some Questions
00:42 Where to Use Distributed IO Systems
01:31 Distributed IO Hardware Components (Network Cable, Gateway, etc.)
02:29 Automation Pyramid: Distributed IO vs Remote IO
03:21 Packaging Machine: An Industrial Automation Application of Distributed I/O Systems
03:59 Distributed IO Modules (Benefits & Features)
5:52 Remote I/O vs Distributed I/O
6:22 Distributed IO Systems as Open Networks
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Glad I found these videos. They are a big help. Thanks

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Excellent! from Brazil thanks.

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[@MiguelLopez-df1to]

Excellent video. Thanks

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Glad you think so! Please let us know if you have any questions or suggestions.

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[@osamayoussef5323]

Really great video, please can you add a video about types of sensors?

[@Upmation]

Sure! We will consider your suggestion. Thank you!

[@hopiegil6141]

Great video and very clear explanation..Can you make a video about two wire network cable?. How it works or transfer supply and data at the same time..

[@Upmation]

Hey! Thanks a lot for both your compliment and suggestion. I will definitely transfer it to the team.

[@patrickkanyangamulumba8157]

Thanks for the video and clear explanation ... waiting for the topic said ... How to choose a IO systems

[@Upmation]

Hi Patrick! You're very welcome and thank you for watching this video! Please stay tuned for the next episodes.

[@md.saddamhosain9134]

Tnx

[@neamotullahjoy2268]

Great explanation from Bangladesh

[@Upmation]

Glad it was helpful and grateful to have you here! Thank you for watching!

[@ejazasif9756]

Perfect animation and explanation.. Glad you are back after long gap.. we are using an AS-i module along with this distributed io’s which means AS-i modules commands field devices ?

[@Upmation]

Thanks a lot! AS interface networks are using Distributed I/O configuration. The IO modules that are used in AS interface networks are not the type that can command the Inputs and Outputs directly. But there are other types of networks with a different type of protocol that utilizes I/O modules capable of some sort of direct commanding to the Inputs and Outputs. These modules, of course, are aimed at controlling the Analogue devices in order to free up the PLC's CUP from extra processing loops and to enhance the automation processes' reliability. Hope this answers your question. If there is any kind of specific subject or expression that might seem vague or intangible to you in this matter then please don't hesitate to let us know and we will try to use them for the next video's subjects.

[@ejazasif9756]

@@Upmation Thanking you on behalf of everyone for replying each and everyone’s comment and thanks for your answer.

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Any time! Happy to help!

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It's very important

[@oleg6517]

Good videos!

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Glad you like them!

[@fredericknunes7329]

Thanks for this beautiful, and knowledgeable class. When are you going to start the trannings. I'am still weating.

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You're very welcome, Frederick! Happy to help! We're trying to manage some time for producing the trainings. Thanks for following up.

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Hello friend!!! A very important video for me!

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Hi, Razer! Thanks a lot for visiting and supporting! Please share this video and let me know about your suggestions.

[@razerimperator231]

@@Upmation I will definitely fulfill your wishes!!! I would really like to see a video about the operation and programming of the ET-200S remote input station.The topic of the operation of frequency converters with Siemens PLC is not fully disclosed in You Tube.In the comments, viewers often ask questions about this.

[@shahedmollick9038]

From Bangladesh thanks

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[@earledaniels4539]

I am an Electrical Design Engineer and even I get confused with the terminology used in automation systems. I think the confusion comes from misuse of system descriptions. The main thing to understand is what equipment and options are available for automation systems these days. It is a rapidly changing industry.

[@Upmation]

Hi, Earle! That was a great point to mention. It is indeed changing rapidly. Please let us know of the challenges you deal with as a Design Engineer and the suggestions you might have for the next videos. BTW, thank you for the input!

[@earledaniels4539]

@@Upmation A video on IEC 61850 basics would be a great topic. There are loads of videos available but they seem to be aimed more at the expert instead of the novice. It would be good to know about the basic message formats and behaviour , ie: cyclic versus subscriber messages

[@Upmation]

Great suggestion! Thanks a lot!

[@mohammedrezk8072]

still get some confusion between both , what can i say that Remote IO is a version type from Distributed IO systems till watching next video of best practices. Thanks too much from Egypt :)

[@Upmation]

Hey, Mohammed! Thank you for your comment! Isn't it better to say the opposite? Both of them are used in remote locations from the main PLC and one of the distinguishing factors is the distance. The other is the speed of the network. By the way, please stay tuned for the next episodes. Thank you!

[@yakikadafi6189]

I was wondering about the repeaters here if they are connected with wires or connected thru WLAN network like a WI-FI between the remote IO and the main PLC ? And thank you in advance sir I appreciate your time and effort 🙏🏽

[@Upmation]

They get connected to the rest of the network with cables. Thank you for your comment and you're very welcome!

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Plc Caterpillar wiring Diagram

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