Decowell Valve Terminal in Automotive Automated Loading and Unloading Systems

1. Project Background

In automotive manufacturing, automated loading and unloading of components and precise assembly are critical to ensuring production efficiency and product quality. A particular automotive parts production line faced the following challenges:

• High precision requirements: Components must be transferred from the conveyor to the assembly workstation with a positioning accuracy of ±0.1mm to ensure seamless integration with the vehicle body.
• Complex signal interaction: The system needs to control multiple cylinder groups simultaneously and collect real-time feedback from over 30 magnetic sensors.
• Wiring optimization pressure: Traditional setups require independent power and signal wiring for each sensor, leading to bulky control cabinets and difficult maintenance.
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2. Solution and the Role of Decowell Valve Terminal

The project utilizes a Siemens S7-1200 PLC as the main controller, paired with the Decowell MTC Series expandable valve terminal to achieve highly efficient integrated control.

1. Multi-Functional Integration of the Valve Terminal

Integrated solenoid valve control and signal acquisition

• The Decowell valve terminal incorporates digital output (DO) modules to directly drive single-solenoid valves, controlling cylinder motion.
• Its expandable input module supports three-wire magnetic switch connections without requiring an external power source. The valve terminal supplies power to sensors and receives signals.

Simplified wiring

• Traditional solutions require separate power and signal wiring for each sensor.
• Decowell’s modular valve terminal integrates power supply and signal transmission, reducing cable usage by over 50%, simplifying wiring, and lowering failure rates.

2. High-Precision Positioning and Motion Control

Accurate cylinder motion

• The valve terminal controls solenoid valve switching via PLC commands, enabling precise component grasping, positioning, and locking.
• A dual verification system combining positioning pins and vision assistance ensures accurate component alignment with the vehicle body.

Real-time feedback mechanism

• 30 magnetic sensors continuously monitor cylinder positions.
• Signals are transmitted through the valve terminal’s input module to the PLC, forming a closed-loop control system to prevent assembly errors due to mechanical deviations.

3. Flexible Expansion and Easy Maintenance

Modular expansion

• The MTC series valve terminal supports hot-swappable I/O modules, allowing flexible channel expansion for production line upgrades or process changes.

Quick diagnostics

• Built-in LED status indicators enable rapid fault identification, reducing average maintenance time by 40%.
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3. Key Benefits and Achievements

Efficiency Improvement

• Cycle time per workstation reduced to 8 seconds, boosting annual production capacity to 500,000 units.
• Positioning accuracy improved to ±0.05mm, reducing defective rates to 0.02%.

Cost Optimization

• 60% reduction in wiring costs and 35% less control cabinet space usage.
• The integrated design minimizes maintenance costs and spare part inventory.

Enhanced Reliability

• The system has operated continuously for 3,000 hours with a 99.8% stability rate.
• The three-wire sensor power supply design prevents voltage fluctuations from causing false triggers.

4. Industry Value and Future Outlook

Decowell’s expandable valve terminal, with its integrated power-control-feedback design, provides a cost-effective solution for automotive automated assembly. Beyond hardware integration, it drives industry advancements in the following areas:

• Intelligent Upgrades: Future support for Profinet/EtherCAT communication enables remote parameter configuration and predictive maintenance.
• Sustainable Manufacturing: Low-power module design supports energy efficiency and carbon reduction, aligning with ESG goals.

Conclusion

As the automotive industry shifts towards flexible and intelligent manufacturing, Decowell’s valve terminal serves as a core neural node in automation equipment. This case study provides a scalable technical framework, helping manufacturers enhance both production capacity and quality while adapting to future challenges.