Decowell Remote I/O Modules Applied in New Energy Lithium Battery PACK Lines

Energy storage battery PACK process refers to the synthesis of multiple individual battery packs into a complete energy storage battery pack, which is an important link between upstream cell production and downstream vehicle or energy storage system applications.

PACK assembly is usually completed on automated production lines, including cell testing, sorting, grouping, assembling, and other key steps, and each step needs to be strictly controlled and managed to ensure the performance and quality of the final battery pack.

01 Understanding the Battery PACK Process

The energy storage battery assembly line is mainly divided into pole piece production, electric cell production, testing, and assembly.

Electrode Manufacturing

The first stage involves producing the battery’s anode and cathode electrodes. This includes mixing raw materials into slurry, coating the slurry onto metal foils, and cutting the foils into electrode sheets suitable for welding tabs. These electrode sheets are then transported in rolls to the next process.

Cell Assembly

In this step, the positive and negative electrode sheets are combined to form single battery cells. The main processes include winding or stacking the electrodes, welding the cell tabs, casing the cells into protective shells, and injecting electrolyte liquid. These procedures transform the electrode materials into fully functional battery cells.

Testing and Final PACK Assembly

The last stage includes formation (chemical activation by placing cells in special containers), capacity testing, and final PACK assembly. Performance and safety of each cell are tested, and only qualified cells are packaged into battery modules for shipment or integration into larger systems.

02 Key Challenges in Lithium Battery PACK Line Automation

Lithium battery PACK lines integrate a wide range of automation components such as photoelectric sensors, proximity switches, pneumatic solenoid valves, and welding robots. Efficient, accurate, and reliable signal acquisition and control are crucial to ensuring smooth operation across the entire line.

To support this, high-performance input-output modules are essential. Decowell remote I/O modules are widely used in stations like welding fixtures, lifting conveyors, and rotary tables to collect sensor signals and control actuators, helping improve automation efficiency and system stability.

03 Decowell Automation Solution for PACK Lines

Decowell remote IO modules are widely applied in key PACK processes after the electrolyte injection step. For example, at a leading domestic new energy company, the PACK line is divided into five zones with high automation levels. The conveyor system uses electric drum motors, and a FANUC six-axis robot handles material handling and palletizing at the line’s end.

The control system uses Omron CJ series PLCs and DeviceNet protocol for network communication. Decowell FS Integrated IO modules — about 300 units — collect signals from sensors and control actuators like robot grippers and pneumatic cylinders. This solution replaces the original Omron local I/O setup, reducing customer costs and improving signal transmission stability.

04 FS Integrated I/O Module Features

• Supports multiple industrial bus protocols, including EtherCAT, PROFINET, DeviceNet, CC-Link, and CC-Link IE Field Basic

• Quick installation with plug-in terminals

• Compact size and tight structural design

• Stable communication with zero data packet loss

• Versatile applications covering logistics, education, automation machinery, and robotic workstations