Application of Solidot Remote I/O Module XB6S in Automotive Ultrasonic Plastic Welding Machines

Ultrasonic plastic welding machines are key equipment in automotive parts production and are widely used in the joining and covering processes of various plastic components. As vehicles become lighter and interior quality requirements rise, the equipment must achieve high-precision control, coordinated motion, real-time status monitoring and safety interlocking, which places high demands on the stability of remote I/O signal transmission.

Solidot products used in this case study

[For the welding process of automotive underbody panels]

XB6S-PN2002

XB6S-3200, XB6S-0032B, XB6S-A40V

[For the covering process of automotive armrests]

XB6S-PN2002

XB6S-3200, XB6S-0032B, XB6S-A08I

1. Production process overview

This equipment is used for both the welding of automotive underbody panels and the covering of armrests. Details are as follows:

[Underbody panel welding process]

Pre-treatment → Positioning and clamping → Ultrasonic emission → Mold melting and fusion → Pressurization and curing

[Pre-treatment]

Clean the surface of the plastic parts to be welded and align them to ensure the welding surface is flat and free of impurities.

[Positioning and clamping]

A pneumatic cylinder drives the fixture to secure the workpiece precisely, preventing displacement during welding.

[Ultrasonic emission]

Start the ultrasonic generator to transmit high-frequency vibration to the welding surface, generating localized heat.

[Mold melting and fusion]

Under the combined action of pressure and ultrasound, the material surfaces melt and interpenetrate, achieving material bonding.

[Pressure curing]

Maintain a certain pressure until the weld seam cools and sets, ensuring structural strength.

[Armrest wrapping process]

Cutting → adhesive spraying → preheating → positioning → mold-press wrapping → trimming

[Cutting]

Precisely cut the skin material according to dimensional requirements to prepare for wrapping.

[Adhesive spraying]

Control the adhesive quantity via a proportional valve and spray the adhesive evenly onto the substrate surface.

[Preheating]

Heat the material moderately to improve flexibility and promote activation of the adhesive layer.

[Positioning]

Precisely position the skin and the frame to prevent wrinkles or misalignment after wrapping.

[Mold-press wrapping]

Apply pressure through the mold so that the skin fits tightly against the frame contour, ensuring a flat appearance free of bubbles.

[Trimming]

Cut off excess material to complete the wrapping finish.

II. I/O module application modes

The equipment uses the PROFINET protocol, with a Siemens S7-1200 series PLC as the master, and connects the individual I/O modules via the Solidot remote I/O XB6S PROFINET protocol coupler XB6S-PN2002 to build a highly reliable communication network. The PLC handles process logic processing and motion control command scheduling, while the remote I/O modules handle field signal acquisition and output execution.

The digital input module XB6S-3200 acquires the detection signals and safety interlock states of the magnetic switches, proximity switches and photoelectric switches at each station in real time; the digital output module XB6S-0032B, with a load capacity of 0.5 A per channel, can directly drive relays and low-power contactors; the analog current output module XB6S-A08I, with high accuracy and high resolution, enables precise regulation of proportional valves and frequency converters; the analog voltage input module XB6S-A40V acquires voltage sensor signals for controlling weld depth.

III. Optimization results of the solution

After the customer adopted the XB6S series products, the remote I/O system achieved significant improvements in noise immunity, convenience and expandability. The XB6S offers excellent overall EMC performance and superior noise immunity, ensuring stable signal transmission; it features diagnostics, alarms and exception logging for easier device maintenance; the analog module provides high accuracy, effectively improving the control precision of devices such as frequency converters and proportional valves; the digital output module offers 0.5 A per channel and 16 A across 32 channels, capable of directly driving relays and low-power contactors.

IV. High-Reliability remote I/O module XB6S Series

The Solidot remote I/O module XB6S series supports multiple bus protocols and offers function modules for motion control, temperature acquisition and more. The products have undergone rigorous EMC testing, delivering superior noise immunity and eliminating disconnections. They support diagnostics, alarms and exception logging for intelligent feedback and ease of use.