Decowell Remote IO Modules Empower Fast Battery Swapping at EV Swap Stations

With the rapid adoption of electric vehicles(EVs)in the market, charging efficiency has become a critical bottleneck in the industry’s development. Unlike traditional refueling for gasoline vehicles, which is quick and convenient, conventional EV charging methods often take a long time, leading to frequent “range anxiety” among drivers.

Battery swap stations have emerged as an efficient alternative solution. By replacing depleted batteries with fully charged ones, swap stations enable a “fast recharge” within 3 minutes, comparable to refueling a gasoline car. The process, including battery removal, replacement, and payment, involves just a few simple steps, making it fast and convenient.

With the support of Decowell remote I/O modules, swap station systems operate with greater stability and faster response times, driving the development of green transportation and intelligent energy management, and injecting new momentum into building a sustainable mobility future.

01 Overview of the Swap Station System Architecture

The efficient operation of swap stations relies on the coordinated work of four core subsystems: the battery swapping system, charging system, swap platform, and control system.

• Battery Swapping System: This is the heart of the station, responsible for removing depleted batteries from EVs and transporting them to the battery storage, while installing fully charged batteries back into vehicles. It mainly consists of swapping robots, locking/unlocking platforms, stackers, and locking components, each handling battery replacement, securing and separating batteries, battery handling, and connection safety. During swapping, multiple high-reliability connectors, such as fast charging connectors, liquid cooling, and water cooling interfaces, ensure efficient and safe operations.

• Charging System: Located onsite, it employs centralized slow AC charging to recharge collected batteries. The battery cabinets feature sturdy structures, environmental adaptability, safety protection, and rapid locking mechanisms to ensure stable charging.

• Swap Platform: Responsible for precise vehicle positioning and swapping operations, typically consisting of the station structure and vehicle docking platform. Common types include recessed (pit) platforms, which are stable and widely used but have longer construction cycles and limited mobility, and lifting platforms, which improve flexibility by raising vehicles for battery replacement but require high precision and compatibility with vehicle suspension systems.

• Control System: Acting as the core coordinator, it receives swapping commands from EVs, orchestrates station equipment, and manages communication. Identification methods include onboard RFID, license plate recognition, and manual identification, ensuring accurate swap operations.

02 Key Challenges at Swap Stations

• Limited Installation Space: Battery storage design demands compact equipment. Decowell EX series remote I/O modules measure approximately 90×67×14 mm, significantly saving space and meeting high-density installation requirements.

• High Signal Transmission Requirements: Coordinated control across subsystems requires stable and real-time signal transmission. The EX series offers high-speed, reliable data processing to ensure uninterrupted operation.

• Complex Electromagnetic Interference (EMI) Environment: High-power, densely packed equipment generates strong EMI during charging. The EX series complies with GB/T EMC Class A standards, demonstrating excellent anti-interference capability and stable operation under harsh conditions.

Swap stations require remote I/O modules to meet these technical criteria:

• Support Profinet communication

• IO installation volume below 20 cm × 15 cm

• EMC performance reaching the national Class A standard

• Centralized external signal acquisition with overall response time under 10 ms

03 Application of Decowell Remote I/O Modules in Swap Stations

• Master Controller: Siemens 151SP

• Application Scenario: Intelligent automatic EV swap stations

• IO Configuration: Each station uses 13–15 remote input output modules, with 96–128 digital IO points per module

Project Overview

This fully automated EV swap station project employs Decowell EX-210H and EX-310H modules for digital input/output acquisition and control. These input output modules manage signals for the lifting platform and rotary mechanisms involved in battery swapping.

The lifting platform requires a signal response time under 20 ms. Vehicle positioning relies on sensor and vision systems, ensuring precise battery removal and installation for safe swapping.

Key Advantages： Decowell remote IO products are highly compatible with Siemens systems, providing a cost-effective, stable imported alternative.

04 Decowell EX Expansion Remote IO Modules Features

• Stable Communication & Fast Response: Ensures efficient control system operation

• Multi-Protocol Compatibility: Supports EtherCAT, PROFINET, DeviceNet, CC-Link, EtherNet/IP, Modbus-RTU, CC-Link IEF Basic, etc.

• Supports Various Signal Types: Digital, analog, temperature, encoder, and free communication input output modules

• Compact Structure: Each module supports up to 32 digital signals, saving installation space

• Strong Expandability: Single adapter supports up to 32 IO modules with high-speed polling

• Easy Installation & Maintenance: DIN-rail mounting with tool-free removal and terminal wiring