Application of Solidot Slice Remote I/O Module XB6S in Aluminum Drawing Machines

The aluminum profile haul-off machine is key equipment in the aluminum processing industry. Its role is to pull aluminum profiles evenly from the extrusion press, ensuring dimensional accuracy and surface quality. As the industry's demand for automation and intelligence continues to rise, the haul-off machine must achieve precise speed control, tension adjustment, and multi-device coordination during operation, which places higher demands on the real-time performance and stability of the control system. By introducing remote I/O technology, the aluminum profile haul-off machine can seamlessly integrate signal acquisition and device interlocking with process parameter optimization, helping enterprises improve production efficiency and product quality to meet the high standards of the modern aluminum processing industry.

Solidot products used in this case study

XB6S-EI2002, XB6S-1616B, XB6S-0016B, XB6S-0032B, XB6S-C01SP, etc.

1. Production process overview

Core process flow of the intelligent aluminum profile haul-off machine: haul-off preparation → haul-off operation monitoring → winding adjustment → finished product output

Haul-off preparation: The operator sets the aluminum profile specifications, haul-off speed, and VFD parameters via the HMI to complete device initialization and ensure the aluminum coil is precisely positioned at the haul-off inlet.

Haul-off operation monitoring: Real-time monitoring of key parameters such as haul-off speed, motor current, and aluminum tension; the closed-loop control system dynamically adjusts the operating state to prevent aluminum deformation or breakage and ensure production continuity.

Winding adjustment: Based on changes in aluminum length and winding diameter, the winding speed and tension are dynamically adjusted to ensure neat winding and prevent quality issues caused by loose or excessive tension.

Finished product output: After haul-off is complete, the aluminum profiles are smoothly transferred to the next process by the conveyor, while production data is recorded for quality traceability and process optimization.

2. I/O module application mode

The system uses the EtherNet/IP protocol. Solidot digital input/output module XB6S-1616B, digital output modules XB6S-0016B/XB6S-0032B, and serial communication module XB6S-C01SP are connected to a Rockwell 1769 series PLC via coupler XB6S-EI2002.

The XB6S digital input modules support multiple signal acquisitions, including emergency stop button status, limit switch signals (for haul-off stroke protection), tension sensor threshold alarms, and proximity switch signals (aluminum coil in-position detection). Their NPN/PNP compatible design accommodates various sensor types, ensuring flexibility and stability of signal acquisition. On the digital output side, output commands control hydraulic lifting platform positioning, lubrication system solenoid valves and auxiliary conveyor rollers, haul-off motors, cooling fans, alarm indicators, winder motor drives, flying shear solenoid valves, and conveyor belt motors. XB6S-C01SP reads energy meter parameters in real time and issues PLC control commands. Together, these enable precise adjustment of haul-off speed, ensuring smoothness and consistency throughout the aluminum profile haul-off process.

3. Solution comparison

The customer's original bus solution suffered from complex distributed wiring, low multi-device coordination efficiency, and large haul-off speed fluctuations. In addition, some modules had weak interference immunity, and electromagnetic interference caused a high signal packet loss rate, frequently leading to production issues such as haul-off roller slippage or aluminum deformation.

After adopting the Solidot remote I/O XB6S series products, the modules deliver high transmission efficiency and strong interference immunity. Haul-off speed control accuracy is significantly improved, closed-loop tension adjustment error is reduced, and aluminum surface quality is notably enhanced. Meanwhile, XB6S digital modules support mixed input/output configuration, reducing wiring complexity.

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

The Solidot remote I/O module XB6S series supports multiple bus protocols and offers function modules for motion control and temperature acquisition. The products have passed stringent EMC testing, providing high noise immunity and preventing disconnection. They support diagnostics, alarms and exception logging for intelligent feedback and ease of use.