Turn Any Solenoid Valve into a Smart, Monitored Device — Without Replacement

Retrofit IO-Link smart connectors transform standard DIN solenoid valves into intelligent devices, adding real-time monitoring, diagnostics and predictive maintenance without system changes. They track coil current, temperature and cycles, reduce energy via PWM, and help prevent downtime. Easy to install, they bring Industry 4.0 visibility to existing pneumatic and process systems at low cost.

Retrofit IO-Link technology brings real-time monitoring, predictive maintenance and energy savings.

Despite the rapid rise of Industry 4.0, one critical gap still exists across most industrial systems — the “last metre”, where solenoid valves continue to operate with no feedback, no diagnostics and no visibility of failure risk.

While control systems, sensors and networks have become increasingly data-driven, the vast majority of installed solenoid valves remain simple switching devices, offering no insight into condition, performance or impending faults.

This lack of visibility can lead to unexpected downtime, difficult fault diagnosis and unnecessary maintenance costs.

A new generation of IO-Link enabled smart connectors is now changing this — allowing standard DIN 43650 solenoid valves to be instantly upgraded into intelligent, monitored devices, without replacing the valve or modifying the system.

These compact devices integrate directly onto existing coils and provide bi-directional communication via IO-Link, the globally standardised interface designed specifically for sensors and actuators.

Unlike traditional connectors, smart connectors incorporate onboard electronics capable of continuously monitoring coil current, temperature, switching cycles and electrical load.

This enables real-time condition monitoring and predictive maintenance — identifying issues such as coil overload, mechanical wear or abnormal operation before they lead to unplanned downtime.

In addition, integrated energy management significantly reduces power consumption. The connector delivers full power during switching, then automatically reduces energy via PWM holding mode, lowering coil temperature and extending service life.

One of the key advantages is retrofit capability. Existing installations can be upgraded in minutes, without changing pipework, valves or control systems — enabling maintenance teams to introduce digital monitoring across legacy equipment with minimal cost and disruption.

Beyond monitoring, smart connectors can also perform simple control functions independently, including timer-based switching and delayed actuation, reducing the need for additional PLC programming.

Typical applications include pneumatic systems, process valves, intralogistics and automated machinery, where improved visibility of valve operation directly improves reliability and reduces maintenance costs.

As manufacturers focus on efficiency, uptime and data-driven maintenance, the ability to transform standard solenoid valves into smart, connected devices offers a practical and scalable route into Industry 4.0.