Solidot's Simplified Wiring Distributed I/O XBF Application in Lithium Battery Module Pack Lines

The lithium battery module PACK line is a core process in power battery and energy storage system production, responsible for assembling individual cells into battery modules that meet specific requirements. Its production equipment involves a massive amount of sensor signal acquisition and actuator control, placing extremely high demands on the bus I/O density, wiring efficiency, configuration flexibility, and maintenance convenience of the control system.

Adopting Solidot's Simplified Wiring Distributed I/O series products can significantly simplify wiring, save on cabling, enhance production line flexibility and maintainability, laying the foundation for efficient and stable large-scale production.

Products Used in This Case:

【Distributed I/O】

XBF4-EC04A、XBF2C-0808A、XBF4-1616A

【Slice I/O】

 XB6S-EC2002

XB6S-3200、XB6S-0032A、XB6S-A40ID

XB6S-C01SP

I. Production Process Introduction

The lithium battery module PACK line mainly includes: Cell Feeding & Inspection → Cell Sorting & Matching → Module Stacking & Fixing → Welding → Module Testing & Curing Assembly → Offline Testing & Capacity Grading (Formation).

II. I/O Module Application

XBF Distributed Core + XB6S Remote Expansion

The system uses the EtherCAT protocol, with a Keyence KV-X PLC as the main controller, building the control network via Solidot's XBF EtherCAT protocol coupler XBF4-EC04A. This coupler provides 4 expansion network ports, each supporting up to 16 I/O modules (total 32 modules). Together with the highly reliable Slice I/O XB6S, it enables full-process signal acquisition and control, supporting various topologies (linear, star, hybrid) for flexible line layout.

III. Solution Optimization Results

• Cost Optimization: Unified power supply via network cables saved 30% on field-side power cables, terminals, wiring, and labor costs.

• Flexible Configuration: XBF coupler's 4-port design supports hybrid topologies and 16 stations per port, enabling flexible layout and easy expansion.

• Efficient Maintenance: Intuitive DIP switch addressing, online diagnostics, logging, and firmware upgrades reduce debugging and maintenance time.

IV. Solidot Simplified Wiring Distributed I/O XBF Series Features:

• Communication via standard industrial Ethernet cables, no special cables/tools needed.

• 3-wire power supply for sensors, eliminating terminal blocks and simplifying wiring.

• Expansion modules don't consume bus node resources, ensuring high system stability.

• Supports linear, star, and hybrid topologies for flexible layout.

• Diverse product forms and protection levels for various scenarios.

• Rapid customization for point count, structure, and special functions.