Nanjing Decowell Automation Co., Ltd. Company Solutions

Case Background: Paper-making machines are essential equipment used to convert plant fibers—such as wood, grass, or recycled paper—into paper through processes including pulping, deinking, sheet forming, pressing, drying, and rolling. Initially, raw materials undergo pulping and deinking to separate fibers. The resulting pulp suspension is then shaped via a wire mesh, mechanically pressed to remove excess moisture, and finally dried and rolled into paper reels. The process involves not only complex mechanical operations but also requires precise control of critical parameters such as moisture, temperature, and pressure to ensure paper quality and production efficiency. Paper-making machines play a foundational role in various industries such as printing, packaging, and stationery. Solution: Main Controller: Siemens PLC Applicable Process: Pulp Separation and Deinking Project I/O Configuration: 1MTC-1110 + 4MTC-210H-A + 4*MTC-310H-A Annual Usage: 300,000 sets This solution integrates Siemens S7-1200 PLC with Decowell’s MTC series valve island modules, forming a high-performance and easily expandable automation control system for paper-making machines. The system receives input from a variety of photoelectric sensors, enabling real-time monitoring of key stages in pulp handling and paper forming. Based on sensor data, the PLC precisely controls essential equipment such as pulpers, motors, forming screens, and dryers, ensuring optimal process performance and product consistency. Thanks to the modular design, the system greatly reduces wiring complexity and provides flexible interfaces for easy expansion of solenoid valves. This intelligent and scalable control system significantly enhances production efficiency and paper quality while reducing energy consumption and manual intervention. Application Advantages: Reduced wiring, streamlined on-site installation Easy solenoid valve expansion for future upgrades Real-time monitoring and precision control ensure high paper yield and uniform quality Stable and reliable system adaptable to various paper-making processes

In high-precision industries such as optoelectronics, semiconductors, and microelectronics, the photoresist coating process plays a critical role in photolithography. As the demand for faster product iterations and tighter yield control increases, coating equipment must evolve to feature more intelligent, flexible, and reliable control systems. Photoresist Coating: Precision Demands Smarter Control This process involves uniformly applying a functional film to a photosensitive substrate, ensuring accurate pattern transfer during subsequent exposure and development stages. Environmental factors like temperature, humidity, and coating thickness must be continuously monitored and precisely controlled to maintain high-quality results. In a recent project, the customer adopted a Siemens S7-1200 PLC as the main controller and integrated it with Decowell's RS Series Profinet I/O modules. The system addressed key challenges such as diverse signal types, multiple control points, and space-limited layouts by implementing a decentralized, flexible I/O solution. Solution Highlights: RS Series I/O Modules + Siemens PLC + Profinet Communication System Configuration: Master Station: 1 × RS-PN2 Digital Inputs: 4 × 16DI Digital Outputs: 4 × 16DO Analog Inputs: 1 × 8AI The entire system communicates via Profinet with the Siemens PLC to gather real-time sensor data and control core equipment such as stir motors, spray units, and heating modules, ensuring optimized coating quality and process stability. Why Choose Decowell RS Series Distributed I/O? Flexible Distributed Installation Modules can be installed near field devices, significantly reducing cable length and wiring time, while streamlining overall deployment. High Compatibility with Mainstream PLCs Full support for Profinet protocol allows seamless integration with Siemens and other major PLC systems, reducing development time and ensuring reliability. Precise Control for Critical Process Parameters Analog modules monitor key variables like temperature, humidity, and coating thickness to maintain optimal process conditions in real time. Scalable Deployment with Stable Supply Chain With an annual volume of over 30,000 units, this solution has been widely adopted across multiple high-end electronic material manufacturing lines with proven stability and performance. Outcome Summary By implementing the Decowell RS Series I/O modules, the coating system achieved: Real-time monitoring of environmental and process parameters Accurate control of multiple actuators Modular system design for easier upgrades Enhanced coating uniformity and product yield As intelligent manufacturing accelerates, flexible, scalable, and easy-to-maintain control systems are becoming essential in production line upgrades. Decowell RS Series distributed I/O modules are fast becoming the preferred choice for advanced photoresist coating applications.

Decowell PLC Solution Empowers High-Efficiency, Stable, and Intelligent Production on a Large-Scale Rice Packaging Line In modern food processing, packaging operations demand precise equipment control and highly stable systems. To address key challenges faced by a client—including excessive vibration, frequent false triggers, poor sealing, and electromagnetic interference—Decowell provided a comprehensive automation control solution based on the MTC series PLC and remote I/O modules. The result: significantly improved system reliability and production efficiency. Project Background Large-scale rice packaging lines typically include feeding, weighing, packaging, and sealing systems. To ensure accurate bag weight, proper sealing, and compliance with hygiene standards, the control system must offer high responsiveness, strong anti-interference performance, scalability, and easy maintenance. Decowell Solution Decowell deployed an automation architecture using MTC series PLCs and remote I/O modules, fully replacing traditional wiring systems to enhance responsiveness and system stability. Key Highlights: Annual Output: Over 2 million units Core Components: MTC-CEC-A series valve island with rapid response and precise control Plug-in Solenoid Valves: Shock-resistant, false trigger-proof, and EMI-resistant Multi-Zone Pressure Control: Single I/O module handles multiple packaging specifications Layered Control Architecture: From information layer – PLC – execution layer – sensing layer; highly scalable and easy to maintain Before & After Comparison: Original System: Complicated wiring, delayed response, and high failure rate With Decowell: Significantly improved response speed Enhanced system stability and flexibility Easy maintenance with true "plug-and-play" functionality Over 30% improvement in overall efficiency Industry Impact This project demonstrates how Decowell's PLC systems enable smart upgrades for traditional food packaging lines. From rice to flour, grains to nuts, our solution is scalable and adaptable to a wide range of food processing applications. Decowell continues to drive intelligent, clean, and green manufacturing through technological innovation—actively contributing to the vision of "Made in China 2025."

In the machining industry, flanges, as key piping connectors, are widely used in petroleum, chemical, electric power and other fields. With the rising demand for personalized orders and multi-specification products, the traditional flange production model faces challenges such as high line changeover costs, multiple manual interventions, and rigid control systems. Flange flexible production line has emerged as an important direction of intelligent manufacturing. Flexible flange production line: a new form of automation and flexibility fusion The so-called flexible production line refers to a production line configuration that can quickly adapt to different specifications and processes. In the processing of flanges, this kind of production line usually includes raw material preparation, forging, machining, heat treatment, surface treatment, assembly and other processes, and the control system must be equipped with the characteristics of “fast switching”, “flexible deployment”, “precise control” and so on. control” and other characteristics. In an actual project, the customer is faced with scattered on-site locations, limited space for installation of electrical cabinets, complex signal locations and other challenges, the traditional centralized wiring can no longer meet the needs of rapid deployment and subsequent maintenance. In this regard, we provide a set of discrete control solutions based on LS series IO. Highlights of the application program: LS discrete IO module + industrial computer + EtherNet/IP The master station of this project uses an industrial computer with LS series IO modules of EtherNet/IP protocol. The configuration in the project includes: LS-EI master station*1 4DI4DO, 8DI, 8DO, 8DI8DO and other modules The whole system distributes control and signal acquisition to different stations through the EtherNet/IP communication protocol, realizing automatic control of the surface treatment and assembly segments. Why choose Decowell LS discrete IO? 1. Extremely high deployment flexibility 2. LS IO modules have the ability to be installed in a distributed manner and can be flexibly placed near each process point, greatly reducing wiring length and construction time. Space saving 3. Signal acquisition and start/stop control can be accomplished without the need for additional control cabinets, which is especially suitable for compact space or retrofit projects. Rapid Expansion to Adapt to Various Process Changes 4. In the face of different flange specifications and assembly processes, only need to modify the local parameters to quickly complete the station adjustment. Unified network management, easy remote operation and maintenance. All IO points are configured under a unified network, realizing real-time monitoring, data collection and remote maintenance, which further improves management efficiency. By adopting LS series IO modules, this flange flexible production line successfully realizes: Multi-point linkage control; Reducing electrical wiring and installation costs; Rapidly adapt to the production requirements of products with different specifications; Enhance the overall production line intelligence level. Under the wave of Industry 4.0 and digitalization of manufacturing industry, flexible, efficient and easy-to-maintain automation control system will become the core demand of workshop upgrading, and LS discrete IO module is becoming the “preferred choice” for more flexible production line projects.

Case Background: A vulcanizing machine is an essential piece of equipment used in rubber and plastic processing. Its main function is to induce a vulcanization reaction by heating and adding sulfur elements, which cross-links the rubber material, enhancing its performance, heat resistance, and elasticity. Vulcanizing machines are widely used in industries such as tire manufacturing, sealing components, and rubber hoses, playing a crucial role in rubber products production. Depending on the application, vulcanizing machines are usually categorized as platen vulcanizing machines and tire vulcanizing machines. The machine precisely controls temperature, pressure, and time to shape the rubber, significantly improving the quality and durability of rubber products. Solution: Main Station: Siemens PLC Applicable Process: Plastic Processing Project I/O Configuration: 1RS-PN2 + 116DI + 1*16DO This solution integrates Siemens S7-1200 PLC with Decowell's I/O modules to create an efficient automation control system for the vulcanizing machine. The PLC receives signals from temperature sensors to monitor the temperature within the vulcanizing chamber, ensuring it remains within the optimal range for vulcanization. Additionally, pressure sensors monitor the device's operating pressure, preventing overpressure. The PLC also drives the heater, pressurizing cylinders, and cooling system motors, precisely controlling temperature and pressure to ensure consistent vulcanization results and high product quality. With this system integration, the vulcanizing machine can achieve a high-efficiency and stable production process, improving both production efficiency and product quality. Advantages of the Application: Multiple Installation Options: The system offers high flexibility, allowing customers to choose the most suitable installation method based on actual needs. Precise Control: Accurate temperature, pressure, and time control ensures consistent vulcanization and enhances the quality of rubber products. High Efficiency and Stability: The system operates stably, improving production efficiency and reducing downtime, ensuring continuous production capabilities. By integrating Siemens PLC with Decowell’s I/O modules, the vulcanizing machine operates under precise control of temperature and pressure, significantly enhancing the quality and efficiency of rubber product production.

Background: Chemical-Mechanical Planarization (CMP) is a crucial process in semiconductor manufacturing, relying on the principle of chemical-mechanical dynamic coupling. This process efficiently removes excess materials from the wafer surface and achieves global nanometer-level flattening with ultra-high flatness, ensuring a surface deviation of less than 5nm. The CMP process consists of two primary stages: chemical and physical. By combining chemical corrosion and mechanical grinding, CMP equipment is vital for the removal of surplus materials and achieving the required global planarization in semiconductor production. CMP equipment is one of the key technologies in semiconductor manufacturing, particularly in integrated circuit production. Its primary function is to achieve nano-level global flattening of the wafer surface, making it one of the most widely used devices in the semiconductor industry for surface manufacturing. Solution: Main Station: Beckhoff PLC Applicable Process Stage: Chemical-Mechanical Polishing (CMP) Project I/O Configuration: 8RS-EC2 + 916DI + 7*8DI8DO In this solution, Beckhoff PLC integrates seamlessly with Decowell’s I/O modules to form a highly efficient CMP equipment control system. This system can receive signals from multiple types of sensors, including photoelectric and position sensors, to continuously monitor the performance of the wafer in real-time. The PLC utilizes these data inputs to precisely control various loads, such as electric drive systems and wafer conveyors, enabling precise polishing operations. Key Benefits: Compact Design: The system is designed to be compact and space-efficient, making it suitable for environments with limited space. High-Speed Response: With a fast response time, the system can handle rapid adjustments during the polishing process, ensuring high production efficiency. Improved Production Efficiency: The system’s precise control over wafer movement and polishing parameters leads to enhanced throughput and higher overall production efficiency. This integrated control system, combining Beckhoff PLC and Decowell I/O modules, optimizes CMP equipment performance, ensuring that semiconductor manufacturers can achieve the highest levels of precision and efficiency in their wafer planarization processes.

We are proud to announce that our MTC-1100 valve island, along with its I/O expansion modules and solenoid valve configurations, has successfully passed EMC testing in accordance with IEC 61000-4-2 / 4-4 / 4-5 standards. Test Highlights: Rated Voltage: 24V DC Hardware Version: V1.2.0 Testing Scope: ESD, EFT, and Surge immunity PLC Model: OMRON NJ301-1100 Auxiliary Modules: MTC-200H/300H-A/D series Load Simulation: 24 solenoid valves with real-time flashing I/O sequences Environment: 25.6°C | 46.8% RH Result: Fully Passed Why it matters: The MTC-1100 system demonstrated strong resistance to electrostatic discharge and transient electrical disturbances, ensuring stable communication, accurate I/O control, and no PLC errors throughout the test. This EMC certification further proves that Decowell’s automation solutions are built for industrial robustness, high reliability, and are ready for CE compliance across global markets. At Decowell, we continue to prioritize the stability and reliability of our products, ensuring they meet the highest standards for industrial applications worldwide.

Application Background In the electric vehicle battery industry, leak detection is a critical process, especially around the welded areas of the battery housing. If the electrolyte inside a lithium battery leaks due to poor sealing, it may react violently with moisture in the environment. This not only poses serious safety and environmental risks but also shortens equipment lifespan and affects long-term product performance. Solution Overview To address these challenges, the project uses a Siemens PLC as the master controller and integrates Decowell's RB Series remote I/O modules. The system consists of three RB-1110 main units, twelve 16-channel digital input modules, and nine 16-channel digital output modules. The annual application volume of this configuration reaches two million I/O points, highlighting its scalability and reliability in large-scale manufacturing environments. The RB Series modules are responsible for controlling high-precision area scan cameras that inspect the top, bottom, and sides of battery covers for defects. Unlike typical field devices that use current-type loads, the industrial cameras in this setup are voltage-type and require only a low-voltage signal to operate. Decowell's RB output modules are designed to be compatible with both current and voltage-type loads, ensuring seamless performance across various sensor types. Application Benefits The RB Series delivers accurate and efficient signal execution, ensuring that inspection commands are transmitted without delay. Its robust design guarantees stable operation in complex industrial environments, making it ideal for high-speed, high-precision processes like battery inspection. By providing consistent, reliable output control, the RB modules enhance system performance and contribute to safer and more efficient EV battery production. Conclusion Decowell’s RB Series I/O modules offer a reliable and flexible solution for modern battery manufacturing lines. By supporting a wide range of sensor types and maintaining high operational stability, they enable manufacturers to meet strict quality standards while optimizing system efficiency. This application is a strong example of how smart I/O architecture supports innovation in the growing electric vehicle industry.

Industry Background Precision machine tools are essential assets in high-end manufacturing, widely used in industries such as aerospace, automotive, electronics, and mold processing. These machines are engineered for exceptional rigidity, stability, and machining accuracy, capable of performing complex tasks like milling, turning, and grinding with micrometer-level precision. To maintain consistent quality and high throughput, modern precision machine tools are equipped with advanced CNC systems and real-time sensing technologies for fully automated control and monitoring. Project Overview To meet the demands of intelligent machining, a control system integrating Siemens S7-1200 PLC and Decowell’s RB Series Remote I/O Modules was deployed across the component processing line. The I/O setup includes: 3× RB-1110 Bus Couplers 8× 16DI Modules 8× 16DO Modules 2× Analog Input (AI) Modules This architecture enables precise signal acquisition and control over critical machine parameters such as tool position, spindle temperature, vibration levels, and feed rate. The system monitors real-time machine conditions and provides high-speed feedback to the PLC, which in turn fine-tunes operations to ensure machining accuracy, process stability, and extended machine lifespan. Why Decowell RB Series? The RB Series Remote I/O Modules offer a compact yet powerful solution for high-end automation applications. Their plug-and-play modularity, industrial-grade stability, and fast response time make them ideally suited for demanding machine tool environments. The modules deliver reliable signal transmission even in high-vibration, high-interference conditions—common challenges in metalworking and milling operations. Designed for seamless integration with Siemens PLCs, the RB series supports a range of digital and analog inputs/outputs, enabling fine-grained control over multi-axis systems and auxiliary equipment. With DIN-rail mounting and easy address configuration, installation time is significantly reduced, which contributes to lower commissioning costs and faster project turnaround. Application Impact With an estimated annual usage of over 200,000 modules, Decowell’s RB Series has become a trusted component in the precision machining sector. Customers benefit from higher machine availability, reduced cycle times, and fewer manual interventions. The consistent performance and flexible I/O scalability make the RB series a future-proof investment for smart manufacturing setups. Conclusion In high-precision environments where every micron counts, control stability and data reliability are non-negotiable. Decowell’s RB Series Remote I/O Modules provide a robust foundation for real-time, distributed machine control. Whether it's capturing vibration signals for preventive maintenance or adjusting feed rates for optimal surface finish, the RB series ensures that precision machines operate at their full potential—efficiently, accurately, and intelligently.

Automation Control Solution for Semiconductor Coating Equipment Case Background: In the semiconductor industry, coating machines are essential in the photolithography process, responsible for applying photoresist or other functional materials onto wafers or substrates. Using spin coating or spray coating methods, these machines form uniform and stable thin films to ensure patterning accuracy. Advanced coating equipment is equipped with precise thickness control, excellent uniformity performance, and high-accuracy positioning systems. They often feature automated loading/unloading arms and real-time feedback control systems to enhance production efficiency and ensure consistent coating quality. Solution: Main Controller: OMRON PLC Applicable Process: Coating Project I/O Configuration: MTC-EEC-A-2-A16-L-10-08-S-D + MTC-200H-D*2 Annual Usage: 1 million sets In this project, the customer integrates an OMRON PLC with Decowell’s MTC valve island products to build a compact and efficient pneumatic control system for coating equipment. Solenoid valves drive cylinders to precisely control the spray nozzle's vertical and horizontal movement, ensuring accurate coating height and position. Additional cylinders drive the automatic loading and unloading arms, which transport substrates between the coater and the conveyor system. The system incorporates I/O modules within the valve island, enabling easy connection of position sensors and magnetic switches. This design reduces wiring complexity and enhances maintainability. With modular architecture, the system offers excellent scalability and flexibility to meet different equipment configurations. Application Advantages: High integration reduces wiring and saves panel space Expandable I/O modules for future system upgrades Accurate motion control for spray nozzles and handling arms Stable, efficient performance suitable for high-volume production

CE certification is a mandatory conformity marking for certain products sold within the European Economic Area (EEA). The letters "CE" stand for "Conformité Européenne," which means "European Conformity" in French. This marking signifies that a product complies with the essential health, safety, and environmental protection standards required by European Union legislation. For manufacturers, the CE mark is not just a formality—it is a declaration that the product meets EU regulatory requirements. It is a legal prerequisite for selling most types of industrial, electrical, and consumer goods in the EU. Without it, a product cannot be lawfully marketed or distributed in any EEA member country. The CE certification process typically includes product testing, risk assessment, technical documentation, and in some cases, third-party evaluation by a notified body. Once all requirements are met, the manufacturer can affix the CE mark to the product and issue a Declaration of Conformity. CE marking applies to a wide range of products, including but not limited to machinery, electrical equipment, medical devices, toys, and construction products. It ensures that consumers and users within the EU can trust that the product is safe, reliable, and fit for its intended use. In summary, CE certification is a critical component of international trade with Europe. It not only demonstrates compliance but also opens doors to one of the world's largest single markets. For businesses aiming to expand into the EU, understanding and obtaining CE certification is an essential step toward global competitiveness.

Industry Background In semiconductor manufacturing, silicon wafers must go through a series of precision processes such as slicing, edge grinding, lapping, surface treatment, polishing, and epitaxial growth. These steps inevitably leave the wafer surfaces contaminated with particles, metal ions, and organic residues. The wafer cleaning stage plays a critical role in removing these impurities to ensure the yield and reliability of the final products. The process demands not only precision but also stability and intelligent control to minimize production loss and contamination risks. Project Overview To address the stringent demands of modern wafer cleaning, the project integrates an Omron PLC as the primary controller, combined with a customized I/O configuration featuring Decowell’s RB Series Remote I/O Modules. The setup includes: 3× RB-1110 Bus Couplers 3× 16DI Modules 3× 16DO Modules 1× Analog Input Module (AI) 1× Analog Output Module (AO) This configuration enables real-time data collection and control across critical cleaning parameters, including equipment operational status, fluid pressure, and chemical concentrations. Decowell RB Series: Compact, Efficient, and Reliable The Decowell RB Series Remote I/O Modules are engineered to meet the high-performance needs of automated process control. Their ultra-slim form factor and DIN rail–friendly design allow for quick deployment, even in space-constrained electrical cabinets. In this application, the RB series enables real-time monitoring and remote diagnostics of the cleaning system, helping technicians identify anomalies such as unstable pressure or improper dosing without the need for on-site inspections. This real-time visibility into system health ensures rapid response to deviations, minimizes downtime, and helps maintain optimal cleaning performance across every wafer batch. Moreover, the modular architecture of the RB Series supports flexible expansion, allowing manufacturers to adapt the I/O scale to different production lines and future upgrades. Application Impact With an annual usage volume exceeding 100,000 units, the Decowell RB Series has proven itself to be a robust, scalable, and cost-effective solution for intelligent wafer cleaning systems. Customers report increased process transparency, improved equipment utilization, and reduced maintenance time. The integration also supports higher-level connectivity, enabling smooth communication with SCADA or MES systems to build a truly smart factory infrastructure. Conclusion In precision-driven industries like semiconductor manufacturing, automation hardware must deliver both reliability and flexibility. The Decowell RB Series Remote I/O solution not only meets the technical requirements of complex wafer cleaning processes but also enhances system integration, scalability, and long-term maintainability—making it a trusted choice for next-generation intelligent manufacturing.