Application of Solidot Remote I/O Module XB6S in Aluminum Shell Motor Valve Threading and Soldering Equipment

The aluminum-housing motor valve wire-threading and soldering equipment must complete processes such as workpiece positioning, wire threading, solder curing and quality inspection. To meet the requirements for high cycle rates, stable soldering and workpiece positioning, the equipment must coordinate multi-axis motion, respond to sensor signals in real time and control actuators. Using the XB6S series remote I/O modules effectively simplifies wiring, improves communication interference immunity and supports production stability.

Solidot products used in this case study

XB6S-PN2002

XB6S-3200, XB6S-0032A

XB6S-PT04A

1. Production process overview

Automated wire-threading and soldering sequence: workpiece positioning → wire threading → soldering machine → quality inspection/unloading

[Workpiece positioning]

The conveyor mechanism transfers the workpiece to the designated station. Once it is detected in position, the positioning mechanism clamps it.

[wire threading]

The wire-threading mechanism starts and precisely threads the wire into the designated position on the workpiece.

[Soldering machine]

Automatic soldering is performed according to the process requirements.

[Quality inspection/unloading]

Finally, continuity and visual inspections are performed. Qualified parts are moved out of the station by the conveyor mechanism, and production data is logged.

2. I/O module application mode

The system uses the PROFINET bus protocol with a Siemens S7-1500 PLC as the control core. The I/O modules are connected via the coupler XB6S-PN2002 and include the digital input module XB6S-3200, the digital output module XB6S-0032A and the 4-channel PTO pulse output module XB6S-PT04A.

The PLC issues commands and acquires data centrally via the XB6S-PN2002: the pulse output module XB6S-PT04A directly outputs pulse trains to control stepper motors and pulse servo motors, enabling workpiece positioning and feeding; the digital input module XB6S-3200 acquires part-in-position signals, limit switch and pushbutton status signals in real time; the digital output module XB6S-0032A controls conveyor start/stop, gripper cylinder actuation, soldering station on/off and device status indicators.

3. Solution optimization results

The customer's original solution relied on PLC bus servo drive positioning, which involved high configuration costs and limited expansion flexibility. After adopting the Solidot remote I/O XB6S products, pulse control is provided via the XB6S-PT04A, saving hardware costs. In addition, the XB6S series products offer good interference immunity, improving production efficiency and stability.

4. XB6S Series High-Reliability remote I/O modules

The XB6S series remote I/O modules from Solidot support multiple bus protocols and offer function modules such as motion control and temperature acquisition. The products have passed strict EMC testing and feature ultra-strong immunity against interference, eliminating disconnections. They support diagnostics, alarms, and exception logging, providing intelligent feedback and ease of use.