Knowledge
The power battery case is a key component of new energy vehicle power batteries. Its machining accuracy and consistency directly affect the safety and service life of the battery pack, which places strict requirements on the reliability of pneumatic control in the production line: clamping, positioning, feeding and other actions are closely interlinked, and any delay in response or incomplete action in any link may affect product quality and line takt time. With outstanding advantages such as high integration, simple piping, fast response and easy maintenance, the fieldbus valve terminal has become the mainstream choice for pneumatic control in this type of production line. This case study takes a power battery case production line as its subject, demonstrating the application practice of the Solidot C3 valve terminal and providing a reference for the upgrade and transformation of similar production lines.
Solidot products used in this case study
C3 series valve terminal (24 positions)
Equipment introduction
In a power battery case production line, each battery case model is generally equipped with a dedicated set of tooling fixtures. During machining, the fixture holds the battery case in place and performs clamping and positioning actions via cylinders, ensuring stable workpiece position and uniform force application, thereby providing reliable assurance for high-precision machining. Around the clamping and positioning process, the main workflow is as follows:
Process step | Action description |
① Clamping and fixing | The battery case is placed into the fixture, and the cylinder clamps and positions it to ensure a stable and reliable machining datum |
② Machining execution | The battery case is machined while firmly secured in the fixture, remaining clamped throughout the entire process |
③ Release and unloading | After machining is complete, the cylinder releases, the battery case is removed, and the cycle proceeds to the next working cycle |
④ model changeover | When changing models, the fixture is replaced, and the pneumatic control points switch over in sync with the fixture |
Solidot solution
The equipment is designed for flexible production of multiple battery case models, and different battery case models require corresponding tooling fixtures. During changeover, the entire fixture is replaced, and the pneumatic control points on the fixture move with it. This solution configures the pneumatic control unit together with the tooling fixture as a set: each tooling fixture is equipped with one C3 valve terminal, and the valve terminal is replaced together with the fixture. On the bus side, only the communication cable and power cable need to be plugged in and out to switch all control points, with no rewiring required. Multiple fixture control units across the entire production line share the bus network, making changeover as simple as plug and play, greatly reducing production preparation time and making changeover operations simpler and more reliable.
Solution architecture
Control layer:
The Siemens S7-1200 PLC serves as the core controller, responsible for logic scheduling of the overall machining process, action sequence planning and takt time coordination, and unified management of all actuators.
Network layer:
The C3 valve terminal is connected to the PLC via the PROFINET fieldbus. A single bus supports flexible deployment of multiple stations, with a concise network topology and clear structure for easy future expansion.
Field layer:
The 24-position C3 valve terminal is mounted directly on the tooling fixture body, driving the clamping and positioning cylinders nearby, shortening the air path and improving response speed. Solenoid valves are fitted according to the actual number of cylinders on the fixture, with surplus valve positions reserved for expansion, balancing current requirements and future upgrades.
Application results
Dimension | Application performance |
Easy changeover | When changing the battery case model, the entire fixture is replaced, and the valve terminal is positioned in sync with the fixture, plug-and-play, fast changeover transition |
Reliable operation | The C3 valve terminal features an IP65 high protection rating and is paired with the company's own-brand solenoid valves, delivering stable and reliable clamping action that effectively ensures machining consistency |
Flexible expansion | Reserve valve positions that are not fully equipped, When additional pneumatic points are needed on the fixture later, solenoid valves can simply be added; capacity expansion requires no changes to the basic hardware equipment. |
Solidot C3 series valve terminal
The Solidot C3 Valve terminal supports up to 24 Double Solenoid Valves and offers IP65 Protection rating for the entire unit, reliably handling harsh industrial environments with dust and oil contamination. The Valve terminal is equipped with in-house Solenoid Valves featuring a low power consumption design and online firmware upgrade capability. It ships fully assembled, and accessory types such as pneumatic fittings can be flexibly configured to suit on-site process requirements. It is compatible with mainstream industrial bus protocols including PROFINET, EtherCAT and EtherNet/IP. With outstanding features of high integration, high protection and easy expansion, the C3 Valve terminal is now widely used in automation scenarios with high cycle rates and high reliability requirements, such as automotive manufacturing, 3C electronics and new energy, helping users build stable and efficient pneumatic control systems.
