Solidot's remote I/O XB6S PTO pulse output module is applied in substrate cutting and stacking systems

The substrate cutting and stacking system is a high-precision production device. Its main function is to cut large sheets of substrate to preset dimensions and shapes and to precisely stack the cut substrates, so as to meet the requirements of subsequent PCB manufacturing processes. It is widely used in PCB manufacturing, electronic component processing and other fields.

The system consists of a multi-axis drive unit, a cutting mechanism, a vision positioning module, a stacking robot arm and a control unit. It significantly improves cutting efficiency and accuracy, reduces material waste, and at the same time meets the processing requirements of complex irregular substrates.

Solidot products used in this case study: XB6S-PN2002, XB6S-3200, XB6S-0032B, XB6S-PT04A, etc.

1. Production process overview

Workflow of the substrate cutting and stacking system: positioning - path planning - cutting execution - stacking control

Positioning: the vision system scans the substrate to acquire the board position, dimensions and contour data, ensuring precise matching of the cutting start point and path.

Path planning: a cutting path is generated based on the design drawing or the machining parameters entered in real time, and the cutter motion trajectory is optimized to improve efficiency and reduce waste.

Cutting execution: the four-axis stepper system drives the cutting head along the preset path in multiple dimensions to complete straight, curved and irregular contour cuts.

Stacking control: the cut substrates are picked up and stacked by the robot arm in a preset sequence, ensuring neat separation without scratches.

2. I/O module Application modes

Conventional cutting systems rely on fixed programming control. When switching between substrates of different specifications, servo parameters and motion logic must be reconfigured, which is time-consuming and requires specialized personnel, thus affecting production efficiency. Customers urgently need a flexible control system that can automatically adapt the cutting path through external input parameters, achieve synchronous high-precision control of four-axis servos, reduce electrical wiring complexity, and improve system response speed and stability.

The system bus uses the PROFINET protocol. The coupler module XB6S-PN2002 serves as the network core node, integrating the digital input module XB6S-3200, the digital output module XB6S-0032B, and the 4-channel PTO pulse output module XB6S-PT04A of the PTO pulse series into the PLC control network, working together to accomplish signal interaction and multi-axis motion control for the substrate cutting and stacking system. Among them, the digital input/output module handles various switch-type signals in the substrate cutting and stacking system, and XB6S-PT04A provides precise control of the four-axis stepper system, mainly involving three categories:

1. Positioning control: Based on the preset cutting program, the host computer sends positioning commands to the XB6S-PT04A module via the PROFINET protocol. After receiving the commands, the module controls the four-axis stepper system through pulse output signals to drive the robotic arm to the specified position, achieving precise positioning of the substrate. The module supports high-precision pulse output and fast response, ensuring the accuracy and stability of the positioning process.

2. Cutting control: After positioning is complete, the host computer sends cutting commands. The XB6S-PT04A module controls the four-axis stepper system according to the commands, causing the motors to perform cutting operations along the preset cutting path and at the preset speed. The module supports multiple motion modes (such as Absolute position mode, Relative position mode, speed mode, etc.), which can be flexibly selected according to actual requirements to ensure high precision and high efficiency of the cutting process. At the same time, the XB6S-PT04A module features Trapezoidal Acceleration/Deceleration, which can smoothly control the acceleration and deceleration of the motors, reducing vibration and impact during cutting and improving cutting quality.

3. Stacking control: After cutting is complete, the host computer sends stacking commands. The XB6S-PT04A module controls the four-axis stepper system to move the cut substrates to the stacking platform and place them precisely according to the preset stacking sequence and positions. The XB6S-PT04A module supports Motion Blending, which allows real-time adjustment of speed, position, and operating mode during stacking, ensuring stacking stability and accuracy. In addition, it also features Homing, which can automatically return the robotic arm to its initial position after stacking is complete, preparing for the next cutting and stacking operation.

3. XB6S-PT04A module Introduction

The XB6S-PT04A module can meet the drive requirements of most stepper/servo motor applications. With features such as high-frequency output, multiple channels, multiple pulse modes, and multiple motion modes, it has been widely used in industrial robot motion control, precision assembly line synchronization systems, packaging machinery timing control, and other fields, providing a solid guarantee for stable operation and efficient production in the automation field.