Nanjing Decowell Automation Co., Ltd. Company Solutions

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.

Industry background： The semiconductor industry is moving towards a new era in the production of nanoscale wafers, which, due to their expensive, precise and fragile nature, place high demands on handling equipment. With advanced automation and control technology, Decowell provides stable and reliable solutions for wafer handling equipment.   The importance of the Decowell FS series： In wafer handling equipment, the Decowell FS integrated remote IO module plays a crucial role. It not only ensures the stability and accuracy of wafers during handling, but also improves the automation and reliability of the entire production line. The FS series I/O module is compact and powerful, which can meet the needs of wafer handling equipment for high precision, high speed and high reliability.   Wafer handling process： In the process of wafer handling, the Decowell FS series IO module works closely with the lithography machine and other equipment to realize a series of automatic actions of the wafer from loading and processing to blanking to the chip box. The efficient and accurate completion of these actions is thanks to the stable transmission and drive control of the FS series IO module.   Decowell Solutions highlights： High-precision transmission: The Decowell FS series IO module has high-precision signal acquisition and processing capabilities to ensure precise control during wafer handling. High speed response: The FS series IO module has a fast response speed, which can meet the needs of wafer handling equipment for high-speed operation. High reliability:Decowell FS Series IO modules use high-quality materials and advanced manufacturing processes to ensure long-term stable operation of the equipment. In summary, the Decowell FS integrated remote IO module plays an irreplaceable role in wafer handling equipment in the semiconductor industry. Its stable, reliable and efficient performance provides strong technical support for wafer handling equipment and promotes the high-quality development of the semiconductor industry.

01 Industry Overview Heavy-duty truck manufacturing includes stamping, welding, painting, and assembly workshops. The painting line is crucial, and electrical automation systems enhance production efficiency. 02 Process Description The painting workshop uses processes like pre-treatment, electrophoresis, body sealing, intermediate painting, topcoat painting, and finishing. Pre-treatment employs silicon-based electrophoresis, and robots handle body sealing. Intermediate and topcoat painting use 3C2B techniques with automated spraying robots. A lab ensures process and product quality. 03 On-Site Challenges Large spaces require a lighting management system, and the intermediate painting process needs specific temperature control. Decowell's products must support Profinet remote I/O, analog I/O, MRP for safety, and centralized signal acquisition with a 10ms response time. Space-saving designs are necessary. 04 Decowell Solution Decowell's EX series card-type I/O is trusted for technical excellence and quality. The Siemens S1500 Series PLC is used, with about 200 digital I/O points. Advantages include stable communication, high analog accuracy, and stable signals. The EX modules control lighting and temperature via frequency converters, ensuring process standards are met. The PLC adjusts temperatures in real-time using EX-4454 and 5414 analog modules, connected to temperature-controlled fans for precise temperature management.

01 Automotive Welding Industry Process The automotive body is a structural component constructed from thin sheets of metal. After being stamped into shape, these sheets are assembled and welded together to form the body shell, also known as the "biw" (body-in-white). Therefore, welding is crucial for body shaping and constitutes a major part of the body manufacturing process. The automotive production line, which includes processes such as welding, stamping, painting, and powertrain assembly, has significantly improved automation levels for automotive manufacturers. The history of large-scale industrial production in the automotive industry has undergone three transformations: the introduction of production lines, platform-based production, and "modular" production methods. 02 Module Application Decowell's solution is applied to the automotive welding production line for welding automotive components such as doors and seats. In this project, the PLC at the main station communicates with Decowell's remote IO modules using the PROFINET communication interface. DI (Digital Input) Modules: Primarily used for APT buttons, fixture positioning sensors, cylinder magnetic switches, door access sensors, and various alarm signal inputs. DO (Digital Output) Modules: Primarily used for fixing welding components (fixtures), cylinders, lasers, and other devices. AI (Analog Input) Modules: Primarily used for pressure sensor detection. AO (Analog Output) Modules: Primarily used for outputting proportional valves. Decowell's remote IO modules provide reliable and efficient communication and control, enhancing the automation and flexibility of the automotive welding production line.

In intelligent storage and logistics systems, continuous conveying equipment is crucial for transporting goods. However, traditional equipment faces issues like complicated wiring, high maintenance costs, and poor adaptability. To address these, we designed an intelligent upgrade scheme for continuous conveying equipment using the Decowell LS module. Our goals include simplifying wiring, reducing maintenance costs, and enhancing flexibility. The Decowell LS module solution simplifies wiring through its self-developed WeIIBUS technology, which connects all slave station equipment with a single cable. It also supports flexible installation outside the cabinet, reducing the need for additional cables and terminal blocks. For maintenance, the WeIlBUS system monitors slave station status in real-time, quickly locating faults and reducing downtime. The provided host software, WellBUSTesterTool, supports functions like slave status monitoring and dot break detection, facilitating field debugging and maintenance. The LS module is plug-and-play, easy to replace and maintain, and equipped with hand-held auxiliary equipment for improved field efficiency. In a project, we used a Siemens main station, applicable to continuous conveying equipment, with an I/O configuration including a PN bus adapter, 30 frequency converters, 10 8DI8DO modules, and 20 4DI4DO modules. The LS-PN master station and slave station modules controlled the equipment and collected position signals, with sensitive and reliable LS discrete IO simplifying wiring and improving device molding efficiency. The project achieved wiring simplification, convenient maintenance, efficiency improvement, and space saving. In summary, the Decowell LS module solution provides an efficient and reliable intelligent upgrade for continuous conveying equipment, aiding enterprises in achieving efficient operation and sustainable development.

TWS headset is mainly composed of a charging box part and a wireless headset part, where the charging box includes devices such as Li-ion battery packs, power PCB components, battery management ICs, LED charging indicator modules, etc., and the wireless headset part includes chips (e.g., Bluetooth chips, power management chips, etc.), sensors (e.g., acceleration sensors, distance sensors, etc.), batteries, microphones, and other electronic devices.   Master station: Omron NX series; Applicable process segments: magnet loading, ear machine cabin pressure preservation ; Project I/O configuration: a single line * 25 EX remote I / O, digital signal * 6000 points; Project Overview: The project for the TWS assembly and test production line, the entire production line of our EX module using the number of 20pcs (EX1100) + 400pcs (DI & DO), mainly responsible for the assembly of the entire production line, the test process of signal acquisition and control, replacing the original OMRON remote IO program; Application advantages: Greatly save the cost and improve the stability of on-site signal transmission.  

Master: PLC (EtherCAT protocol) Applicable process sections: IC package inspection Project I/O Configuration: FS1, EX series I/O Project Overview: In the solid crystal machine using our FS1 and EX two series of remote I / O, where the digital input signal is mainly to assume the material tray points in place signal, the output signal corresponds to the solenoid valve and clamp suction cup, analog module is mainly applied to the material tray motor drive. Application Advantage: Provide customers with standardized solutions, a single station can use the same series of various types of I/O, improve the overall efficiency of the project. Application advantages: Provide customers with standardized solutions, a single workstation can use the same series of various types of I/O, to improve the overall efficiency of the project. EX Series Card Type I/O Product features: 1. Stable communication, fast response, convenient operation and high efficiency; 2. rich bus protocols, support a variety of communication protocols, such as: EtherCAT, PROFINET, DeviceNet, CC-Link, EtherNET/IP, Modbus-RTU, CC-Link IE Field Basic and so on; 3. Signal types are abundant to meet factory automation and process automation control. Support digital, analog, temperature module, encoder module, free communication module; 4. compact structure, small module size, a single I/O module supports a maximum of 32 digital signal points; 5. strong expansion capability, a single adapter can expand up to 32 pieces of I / O module, coupler scanning speed; 6. simple and easy to use, standard DIN35 rail mounting, direct plug-in terminals, tool-free installation.  

In the highly competitive and fast - evolving cosmetic packaging industry, where Industry 4.0 and smart manufacturing trends are taking center stage, the performance of equipment is a make - or - break factor for enterprises. The Decowell RS series multi - functional integrated I/O has emerged as a game - changer, becoming the focus of the industry with its powerful capabilities. Exceptional Anti - interference Performance In the complex electromagnetic environment of the workshop, which is a common pain point in the industry, signal transmission of traditional equipment often malfunctions. However, the RS series I/O stands out. With a response time within 3ms, it remains rock - steady even in extreme temperatures ranging from - 25°C to 60°C. Its EMC standards far exceed national requirements, endowing it with super - strong anti - interference capabilities. With a high - speed data transfer rate of 100Mbps and a unique communication interface, signal transmission is seamless, ensuring smooth operation in the era of high - speed digital communication. Leading - edge Maintenance Convenience Troubleshooting traditional packaging equipment is often like looking for a needle in a haystack, and replacing components is a daunting task. The RS series I/O addresses these pain points head - on. Thanks to its modular design, a hot topic in modern industrial design, the structure is clear at a glance. It comes with a self - diagnosis function, a key feature in smart manufacturing, which can quickly pinpoint faults. The hot - swap function is truly remarkable. Workers can replace modules during equipment operation without shutting down, an essential feature for minimizing downtime in lean manufacturing. This significantly reduces maintenance costs and difficulties, making maintenance a breeze. Multiple Highlights in Functional Design The modular split - type design of the RS series allows for flexible configuration according to specific needs, highlighting customization, a buzzword in the industry. The I/O panel supports hot - swapping, enabling quick adaptation to production changes. It offers diverse installation methods, easily fitting into different spatial layouts. Its compact size saves approximately 60% of the installation space compared to traditional equipment, which is crucial for optimizing factory floor space. Equipped with a dust - proof cover, it can be installed outside the cabinet, expanding its application scenarios. With flexible fault diagnosis and software settings, and the ability to freely match signal types, the system is highly intelligent and adaptable, meeting the requirements of intelligent production. The Decowell RS series, with its outstanding performance, provides an efficient, stable, and intelligent solution for cosmetic packaging, helping enterprises gain a competitive edge in the market and ride the wave of industry transformation.