Nanjing Decowell Automation Co., Ltd. Company Solutions

In the fiercely competitive headphone manufacturing industry, product quality and production efficiency are key to success. Glue dispensing, a critical process ensuring the quality and stability of headphones, demands high precision, stability, and automation. Decowell's RS Series I/O modules, with their exceptional performance, are revolutionizing the headphone glue dispensing lines. Complex Process, Precise Control Headphone glue dispensing lines consist of precise components, including the dispensing head, conveyor belt, control system, and visual inspection system. The dispensing head uses high-precision nozzles to apply glue accurately to designated spots on headphone components. The conveyor ensures smooth movement between workstations, while the control system fine-tunes the dispensing parameters. The visual system monitors in real-time, preventing issues like glue leakage or over-application. Any deviation in the process can affect headphone quality. RS Series, Perfectly Aligned In this project, Omron serves as the main station, seamlessly integrating with Decowell’s RS Series I/O modules to provide strong support for the headphone assembly process. With approximately 80 digital input points and an annual demand of 3 million, this solution is crucial for large-scale production. Outstanding Performance, Comprehensive Improvement Stable & Reliable: The RS Series ensures the steady operation of the glue dispensing line. It performs consistently even in long hours of high-intensity production, minimizing downtime and ensuring production continuity. It meets the strict stability requirements of large-scale production. Quick Installation, Time Saving: Designed for easy installation, the RS Series significantly shortens setup and debugging times. Compared to traditional I/O modules, it helps get the dispensing line up and running faster, saving labor and time costs, and giving companies a competitive edge in the market. Smart Diagnostics, Fast Recovery: With advanced diagnostic features, the RS Series I/O modules quickly locate issues during operation. When a fault occurs, it pinpoints the exact problem, enabling rapid repair and minimizing downtime, improving overall productivity, and reducing losses from equipment failure. Decowell's RS Series I/O modules are perfectly tailored to the needs of headphone glue dispensing lines. With stable performance, easy installation, and smart diagnostics, they provide an efficient and precise production experience, helping companies excel in a competitive market and lead the way in acoustic product manufacturing.

1. Overview of the Test Product Tested: EX Series CC-LINK-IE F Basic Bus I/O Module Model: EX-1140 Test Standards: IEC 61000 Series Test Objective: Evaluate the product’s capability to resist common industrial environmental interference, including Electrostatic Discharge (ESD), Electrical Fast Transient (EFT), and Surge conditions, to ensure stable and reliable performance in demanding settings. 2. Summary of Test Results Electrostatic Discharge (ESD): Passed (IEC 61000-4-2) Electrical Fast Transient (EFT): Passed (IEC 61000-4-4) Surge Immunity: Passed (IEC 61000-4-5) The EX-1140 I/O module successfully met all test requirements, demonstrating compliance with the relevant IEC standards. 3. Detailed Test Results 3.1 Electrostatic Discharge (ESD) Test Test Voltage: Contact Discharge: ±4KV (Grade A) Air Discharge: ±8KV (Grade A) Test Observations: At ±4KV, the I/O module and its cascaded components maintained normal operation. At ±8KV, the system, including system power, I/O power, and DIP switch functionality, showed stable performance without any disruption. Test Environment: Temperature: 15.2℃ Humidity: 35% 3.2 Electrical Fast Transient (EFT) Test Test Levels: Power Interface: ±2KV (5KHZ/100KHZ, Grade A) Signal Line Interface: ±1KV (5KHZ/100KHZ, Grade A) Test Observations: The EX-1140 and its cascaded components maintained stable operation under all specified EFT test conditions. 3.3 Surge Immunity Test Results: The module passed the surge test, meeting the IEC 61000-4-5 standard for surge immunity. 4. Functional Retesting Results After completing the immunity tests, functional retesting was conducted to verify the module’s performance. The results were as follows: PLC Communication: Normal I/O Input: Normal I/O Output: Normal Status Indicators: Normal The EX-1140 I/O module exhibited consistent and reliable functionality post-testing, confirming its robustness and reliability under challenging conditions. 5. Conclusion The EX Series CC-LINK-IE F Basic Bus I/O Module (Model: EX-1140) successfully passed all immunity tests, demonstrating: Strong resistance to electrostatic discharge (ESD), electrical fast transients (EFT), and surge interference. Compliance with stringent IEC 61000 series standards. Reliable and stable performance in industrial environments. This test confirms that the EX-1140 module is highly reliable and well-suited for industrial automation applications where immunity to interference is critical. For further inquiries or detailed test data, feel free to contact us.

  In Nanjing Decowell's array of industrial control solutions, the EX Series has demonstrated significant advantages and a core role in the equipment manufacturing industry, particularly in the production lines for electric tool motor rotors. The compact design and powerful scalability of the EX Series card I/O modules seamlessly integrate into the complex environment of electric tool motor rotor production lines. These modules are not only small in size, allowing for flexible deployment, but can also expand to support up to 32 I/O points through a single adapter, meeting the production line's high demand for numerous I/O points. In terms of communication, the EX Series employs advanced communication technology to ensure stable and responsive communication between the PLC and the I/O modules, which is crucial for enhancing overall production efficiency. In the electric tool motor rotor production line, Decowell cleverly incorporates the EX Series I/O modules as part of a distributed processing solution, working in tandem with Omron's NX series PLCs. The EX modules are responsible for the collection and transmission of critical signals such as position detection and fixture detection, ensuring that every action on the production line is precisely controlled. This design not only enhances the automation level of the production line but also significantly improves production efficiency and product quality. Additionally, the EX Series I/O modules support various communication protocols and signal types, including digital, analog, and temperature modules, providing a rich selection for factory automation and process control. This flexibility allows Decowell's solutions to easily adapt to different brands and models of equipment, effectively supporting the diverse needs of the equipment manufacturing industry. In summary, Decowell's EX Series products, with their compact design, robust scalability, stable communication performance, and diverse signal type support, play a key role in electric tool motor rotor production lines, providing efficient and reliable solutions for automation in the equipment manufacturing sector.

Decowell's FS integrated module plays an important role in the air conditioning production line.   The FS module is mainly applied in the air conditioning production line, covering the entire conveyor line from feeding, assembling, testing to unloading. At present, this module is mainly supplied to well-known manufacturers such as Gree, Midea, and Haier.   In the air conditioning production line, the equipment main station uses FX3U-128M + FX-16CCL-M, and adopts the CC-Link protocol combined with Decowell's FS series integrated module. Mainly through the FS integrated module to control relays and contactors, and then control the start and stop of three-phase asynchronous motors. At the same time, the FS module is used to control the operation of the motor through the switch quantity via the frequency converter, thereby realizing the conveying work of the production line.   After market verification, Decowell's FS integrated module shows excellent performance and stability in the air conditioning production line, providing efficient and reliable automation solutions for air conditioning production enterprises.

Industry Background and Wet Process Analysis： Industry Background: Solar PV generation is pivotal in addressing global energy shortages, with electrical automation enhancing solar cell production. Wet Process Analysis: The wet process in solar cell manufacturing is challenging, with fleece playing a crucial role in photoelectric conversion efficiency. Fleece Process and On-site Challenges： Fleece Process: Fleece enhances solar cell efficiency by improving light scattering and absorption. On-site Challenges: Long equipment setups, high wiring costs, complex construction, and troubleshooting difficulties hinder production efficiency. Decowell Solutions and Application Case： Decowell Solutions: Decowell's FS series IO resolves wiring, construction, and troubleshooting issues, ensuring production stability and cost-effectiveness. Application Case: In a leading PV base, over 30 FS IO modules seamlessly interact with servo motors and robots, meeting production needs with 1000 digital I/O points. Decowell's solution improves efficiency, reduces costs, and solves on-site issues, contributing to the solar power industry's success.

First, the terminal machine introduction The terminal machine is a commonly used machine for wire processing, which can press the hardware head to the wire end to do conduction. The printed terminal is convenient for connecting two wires, without welding and easy disassembly. Various types of terminal machine, including automatic terminal machine, stripping terminal machine, super mute terminal machine, pneumatic terminal machine, terminal machine, computer wire automatic peeling end machine, pin machine terminal machine, gold wire terminal machine. Automatic terminal machine can realize unmanned guard, reduce labor costs, reduce accident rate, improve production efficiency and output. Second, terminal machine work flow The work flow of the terminal machine includes cutting the line, peeling the head, dividing the line, identifying the color, hitting the terminal, peeling the tail, etc. Topology of the terminal control system The industrial computer uses the standard industrial Ethernet bus EtherCAT protocol to connect with the remote IO. The EX-1110 is an EX series EtherCAT adapter that supports up to 32 IO modules and EtherCAT ring network. The EX-200H is a 16-channel digital input module (NPN), which mainly collects digital signals such as sensors and external buttons. The EX-300H is a 16-channel digital output module (NPN), which mainly outputs the control equipment operating status indicator, intermediate relay, solenoid valve, etc. The IO used in this case is the EX series card bus I/O module, which was released in 2018, and the adapter protocol is diversified. Supports EtherCAT, PROFINET, PROFIBUS DP, DeviceNET, CC-Link, CC-Link IE Basic, Modbus RTU, EtherNET/IP and other bus protocols. The expandable IO modules in the adapter include digital input/output, analog input/output, thermocouple/thermal resistance and other modules.

Application of Decowell EX Series Card-type I/O on the Automobile Welding Production Line   The automobile body is composed of thin plates. The sheet materials after stamping are assembled and welded to form the body shell, also known as the body in white. Therefore, welding is the key to body forming and a major part of the automobile body manufacturing process.   The automobile production line is a flow production line for manufacturing automobiles. Due to the presence of processes such as welding, stamping, painting, and powertrain assembly, the automation level of automobile manufacturers has been improved. The development history of the mass production mode of automobiles has witnessed three transformations: the production line mode, the automobile platform production mode, and the "modular" production mode.   The Decowell project is applied to the automobile welding production line for welding automobile parts such as car doors and seats.   In this project, the PLC adopted by the master station communicates with the Decowell remote I/O modules through the PROFINET communication interface of the PLC itself.   Among them, the DI (Digital Input) modules are mainly used for inputting signals such as APT buttons, fixture in-place sensors, cylinder magnetic switches, access control inductions, and various alarm signals; the DO (Digital Output) modules are mainly used for fixing welded parts (of fixtures), cylinders, lasers, etc.; the AI (Analog Input) modules are mainly used for detecting pressure sensors; and the AO (Analog Output) modules are mainly used for outputting proportional valves.

In today's rapidly evolving logistics industry, the demand for efficient and accurate sorting systems is on the rise. As the volume of express logistics business surges and industries like manufacturing, medicine, and food increasingly require logistics automation, intelligent logistics sorting systems are witnessing significant growth. The electrical control system of these intelligent sorting systems is of utmost importance, and within it, the remote I/O plays a crucial role. Decowell's LS series stands out in this regard. Logistics sorting systems often face challenges such as high wiring costs. The complex wiring not only increases installation difficulty and workload but also incurs substantial material costs. However, the Decowell LS series offers a wiring-saving solution that is concise and easily expandable, saving 50% of wire materials and reducing wiring time by 35%, enhancing system neatness and reliability. Another pain point is difficult fault diagnosis. High equipment failure rates can disrupt operations and increase maintenance costs. The LS series comes with rich diagnostic functions like undervoltage, overvoltage, and wire breakage detection, enabling easier monitoring and troubleshooting. Moreover, its plug-and-play modules and handheld auxiliary devices facilitate maintenance. High real-time performance is also essential. Logistics sorting systems need to process and transmit large amounts of item information quickly to make accurate sorting decisions. The Decowell LS series excels in this aspect, enabling the equipment to sort 1,000 times per minute with reduced signal transmission delay. In a specific logistics sorting project, the system uses conveyor sorting and is equipped with the Decowell LS series discrete I/O modules. With Siemens as the master station, it identifies express information through the vision system and sorts parcels by region. The LS series features free choice of communication cables, two-core transmission, rich diagnostics, flexible topology, high anti-interference, plug-and-play functionality, and infrared handheld devices. Overall, the Decowell LS series is a valuable solution for enhancing the efficiency and performance of logistics sorting systems.

Recently, our overseas customers conducted a comprehensive performance test on Decowell's industrial automation products. The results once again confirmed their exceptional quality, reliability, and capability to perform in demanding environments. Below is a detailed overview of the tested products, methodologies, and outcomes. Tested Products RB-1130 I/O Module: Delivered stable signal transmission with a 24V input voltage. RB-0100 Power Supply Module: Provided reliable power support for systems across diverse environments. RB-200H Discrete Input Module: Operated flawlessly with 16-channel dry contact input. RB-4054 Analog Input Module: Accurately processed multi-range analog inputs. RB-300H Discrete Output Module: Ensured seamless 16-channel output transmission. SDEC-8IOL-M12-00 EtherCAT Connector: Maintained outstanding communication stability under high temperatures. SDIOL-08N0-M12 IO-Link Slave: Delivered efficient 8-channel output with robust performance. Testing Stages and Results Stage 1: Room Conditions Testing (24℃, ~30% Humidity) Using IOTesterTool and CODESYS software, all devices were tested under standard room conditions. The results showed exceptional speed and accuracy in signal transmission, with devices performing without any issues. Stage 2: Thermal Chamber Testing (45–50℃) The equipment was exposed to elevated temperatures in a thermal chamber for 40 minutes while maintaining data reception through the CODESYS environment. The devices continued to perform with consistent speed, accuracy, and stability, even under thermal stress. Stage 3: Extreme Heat Testing (60–64℃) Critical components, such as the SDEC and SDIOL devices, remained inside the thermal chamber as the temperature was increased further. After 40 minutes, the devices showed no interference or distortion, and real-time connections remained seamless. The equipment demonstrated superior durability and reliability, with temperature increases remaining within acceptable margins. Customer Feedback Highlights Stable Performance: The products operated smoothly without any interruptions or distortions. Durability Under Stress: All devices performed effectively at elevated temperatures, maintaining operational integrity without significant overheating. Ease of Integration: The equipment integrated seamlessly with CODESYS, ensuring compatibility and efficiency in industrial environments. Conclusion These tests reinforce Decowell’s commitment to providing industrial automation solutions that meet the highest performance and reliability standards. Our products are designed to operate flawlessly, even in extreme conditions, delivering consistent results and adding value to your industrial processes. If you are looking for high-performance, durable, and reliable industrial automation solutions, contact Decowell today to discover how we can optimize your operations.

The following is an application case of Decowell Remote IO in the home appliance industry: 1.1 Air conditioner production line Mainly used in air-conditioning production line, from loading assembly testing to discharging the whole line of the conveyor line. At present, it is mainly supplied to Gree, Meitai, Haier and other famous manufacturers. 1.2 System topology of air conditioner production conveyor line The master station of this equipment uses FX3U-128M+FX-16CCL-M with Dekvil FS series all-in-one module using CC-Link protocol. Mainly through the FS all-in-one module to control the relay, contactor and then control the three-phase asynchronous motor start and stop. The goods value uses the FS module to control the operation of the motor through the inverter via the switching quantity. Thus realizing the conveying work of the production line.  

In the manufacturing process of new energy power batteries, cell baking is a key step to ensure battery performance. Thanks to their superior performance, Deckwell IO modules are ideal for cell baking processes.

  Industry background： The core process of lithium battery cell manufacturing includes winding and welding. The winding process requires high precision and stability of the production line, and the welding process uses laser/ultrasonic welding technology to ensure a solid connection between the battery cell and the shell.   Field challenge response： Stability and speed: Decowell EX series remote IO module with its excellent performance, ensure the stability of the winding machine at high speed operation, to meet the production line for high precision requirements. Assembly efficiency: Decowell EX series modules are compact and easy to use, support a variety of communication protocols and signal types, simplify the assembly process and shorten assembly time. Customized solutions: For the special needs of lithium battery cell manufacturing, Decowell offers customized EX Series IO modules, such as a wide temperature range and three-resistant paint version, to ensure long-term stable operation of the equipment.   Case highlights： Precise control: By optimizing communication protocols and signal processing technology, Decowell EX series modules achieve seamless docking with the winding machine to ensure accurate control of the cell winding process. Efficient production: After the introduction of Decowell EX series products, the production efficiency of lithium battery cell manufacturing enterprises has been significantly improved, and the product quality is more stable and reliable.   Customer trust: Decowell EX series products have won wide praise and trust from customers for their excellent performance and customized services.