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.