Nanjing Decowell Automation Co., Ltd. Company Solutions

In the field of automated packaging, rice packaging equipment typically consists of several key systems, including the feeding system, weighing system, packaging system, and sealing system. These systems need to work accurately and efficiently to ensure that each bag of rice meets quality and packaging standards. Among them, the valve terminal system plays a crucial role in ensuring the stability, reliability, and efficiency of the production process. Project Background and Challenges A customer of a rice packaging equipment manufacturer had initially adopted an external wiring terminal block solution. However, during actual operation, several issues were identified, especially in an environment with equipment vibrations and rice splashing. The previous solution posed a risk of valve control failure, which not only impacted equipment performance but also affected packaging quality and the overall stability of the production line. Solution: Decowell MTC Series Valve Terminals To address these challenges, the customer chose to replace their existing solution with the MTC series valve terminals from Decowell. The specific configuration provided for the project was as follows: Main Controller: Megmeet PLC Valve Terminal Configuration: MTC-CEC-A-2-A12-L-10-06-S-A MTC-EEC-A-2-A8D1-B-10-06-S-A Applicable Process Stage: Inner vacuum packaging This configuration offered the customer a more stable and efficient solution, especially when handling complex environmental conditions such as vibrations and rice splashing. Unique Advantages of Decowell Valve Terminals Strong Vibration Resistance The MTC series valve terminals from Decowell use plug-in solenoid valves, which significantly enhance vibration resistance. The plug-in design provides a stable and secure connection, preventing control failures caused by equipment vibrations and ensuring long-term stability in operation. This feature is particularly important in the rice packaging industry, where vibrations and external disturbances are common. Reliable Connection Method The plug-in solenoid valve design not only offers a compact structure but also improves connection reliability. Compared to traditional external wiring terminal blocks, Decowell’s valve terminals provide a more stable connection, effectively eliminating the risk of loose or disconnected wiring. This reduces maintenance costs and downtime due to faults. Pressure Zone Functionality A key advantage of Decowell valve terminals is the ability to create pressure zones. Multiple supply pressures can be configured within a single valve terminal, allowing different parts of the system to operate at distinct pressures. For example, certain cylinders in the rice packaging process may require high-pressure drives, while others need low-pressure support. The pressure zone functionality makes it possible to meet these diverse requirements, improving overall system efficiency and reliability. High Protection Rating The MTC series valve terminals feature a high protection rating, effectively preventing contamination from rice splashes and other materials. This robust protection ensures that the solenoid valves remain unaffected by environmental factors, maintaining high performance even in harsh conditions. This feature is especially critical in the food packaging industry, where cleanliness and operational integrity are essential. Conclusion Decowell’s MTC series valve terminals offer a reliable and efficient solution for rice packaging equipment. Through their vibration resistance, high protection, and pressure zone functionality, they successfully address the valve control failure risks present in traditional equipment solutions. These technical advantages not only enhance the stability and productivity of the equipment but also reduce failure rates and maintenance costs, resulting in a more reliable and efficient rice packaging process. If you would like to learn more about the technical features and applications of Decowell valve terminals, feel free to contact us. We will be happy to provide you with customized automation solutions for your specific needs.

When it comes to product distribution, reliable packaging has a direct impact on product integrity. In order to ensure that RS products are safe and sound during transportation, we have conducted rigorous packaging drop tests in accordance with relevant standards. I. Reference Standards This test is conducted in strict accordance with GB/T 2423.8-1995, which is the industry authority and provides support for scientific evaluation of product performance under drop impact. II.Test Methods Appearance inspection: Before the test, carefully check the appearance of the package and the product to ensure that there is no damage and to provide an accurate benchmark for the subsequent test. Accurate weighing: The finished package is placed on the balance and weighed accurately, the weight data determines the height of the drop, which is related to the scientific nature of the test. Drop operation: According to the standard, the drop height of 0-9Kg products is 760mm, and the drop height of 9.1-22Kg products is 610mm, and the drop direction covers one corner, three prongs and six surfaces to simulate accidental drops during transportation. Drop Review: After the drop test, check the package and the product again to see if there is any damage. Function test: Connect the IO device to the PLC and test its communication, input and output functions to ensure that the core performance of the product is not affected III.Test Results After the test, the RS product performs well. The package is only slightly worn, and there are no scratches, dents or damages on the product's appearance. In the function test, the communication between IO device and PLC is smooth, and all functions run stably and meet the design standard. The test proved that RS products have excellent packaging protection performance, can effectively withstand the impact of falling, and the product performance is stable and reliable, facing the complex transportation environment and accidental falls, can be handled with ease, and bring consumers a high-quality experience.

In the surging wave of modern manufacturing's booming development, precision machine tools, as the core equipment for producing high - quality products, have their performance directly determining the accuracy of products and the competitiveness of enterprises. With the rapid advancement of technology, the demands for precise control and real - time monitoring of precision machine tools are becoming increasingly urgent. The Decowell RB series of ultra - thin and light card - type I/O modules emerges at the right moment. Collaborating with Siemens 1200 PLC, it brings a brand - new solution to the field of precision machine tools. Industry Focus: The Crucial Role of Precision Machine Tools Precision machine tools, with their characteristics of high rigidity, high stability, and high precision, are widely applied in high - end manufacturing fields such as aerospace, automotive, mold, and electronics. They are capable of machining complex - shaped parts through processes like milling, turning, and grinding, serving as the cornerstone of modern manufacturing. Usually equipped with advanced numerical control systems and measuring devices, precision machine tools achieve automated control and real - time monitoring, ensuring precision and consistency during the machining process. Addressing Pain Points: The Dilemmas of Traditional Electrical Control Signal Interference Challenges The electrical control systems of precision machine tools are often plagued by signal interference. Electromagnetic interference from high - voltage electrical equipment, high - frequency signal radiation, and harsh environments can all cause signal distortion, affecting the operation of machine tools and machining accuracy. It may even lead to malfunctions and equipment damage, severely restricting the improvement of machine tool performance and reliability. Complex Wiring Dilemmas The complex wiring in the electrical control systems of precision machine tools is a prominent issue. A large number of cables intertwined not only increase the installation and maintenance costs but also easily cause signal interference and potential faults. Troubleshooting is like searching for a needle in a haystack, greatly affecting the operating efficiency and reliability of machine tools. Poor Compatibility Dilemmas In the electrical control systems of precision machine tools, the poor compatibility of I/O modules is a significant problem. Difficulties in communication and collaboration between different modules increase the difficulty and cost of system integration, leading to frequent faults and malfunctions. This problem becomes more prominent during system upgrades or expansions, restricting the integration of machine tools with other advanced technology equipment. RB Series: A Comprehensive Solution Outstanding Anti - interference Capability The Decowell RB series demonstrates remarkable performance in communication stability. It can operate stably in extreme temperature environments ranging from - 25°C to 60°C. Its EMC tests far exceed national standards, effectively resisting electromagnetic interference. The gold - plated connectors are resistant to oxidation and corrosion, and the 45 - degree inclined communication interface design reduces stress, ensuring stable signal transmission. Concise Wiring Advantages The ultra - thin design of the RB series saves a large amount of installation space. The unique connection method reduces the number of cables, and the high integration degree reduces the need for external wiring. The stable and reliable signal transmission fundamentally solves the problem of complex wiring. Ultra - high Compatibility The RB series exhibits over 95% high compatibility and can be perfectly adapted to a variety of mainstream brands and models of equipment. It can ensure accurate data transmission in various working environments and application scenarios. A Powerful Alliance: The Perfect Match with Siemens 1200 PLC The combination of Siemens 1200 PLC and Decowell RB series I/O modules constructs an efficient precision machine tool control system. This system can receive signals from various sensors in real - time, including position sensors, temperature sensors, vibration sensors, and feed sensors, comprehensively monitoring the working status and machining process of machine tools. Through the precise analysis of data by PLC, it realizes precise control and adjustment of machine tools, ensuring high - precision machining and stability. This combination significantly improves machining efficiency, reduces errors, and extends the service life of equipment, perfectly meeting the ever - increasing demands for precision and efficiency in modern manufacturing. The Decowell RB series, with its excellent performance and perfect match with Siemens, brings a leap in the performance of precision machine tools, helping modern manufacturing move towards new heights.

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.