The application of Solidot I/O modules on the photovoltaic glass automatic packaging assembly line

Traditional photovoltaic glass factories mostly use manual methods to package stacked photovoltaic glass, resulting in low work efficiency and high labour intensity. Upgrading to an automated packaging method can greatly reduce workers' labour intensity and lower labour costs, significantly improve work efficiency, and also ensure the consistency and quality of the packaged products.

In response to the above requirements, the automatic photovoltaic glass packaging line was developed. It can automatically perform processes such as strapping, film covering, and film wrapping on stacked photovoltaic glass without manual operation, and both the front and rear ends can be designed to connect with AGV forklifts to achieve automatic loading and unloading of glass stacks.

This case study uses Shidian Technology products XB6-PN2002ST, XB6-3200B, XB6-0032B, and others.

Production Process Overview

Process flow: feeding — centering — long-side inner strapping — buffer 1 — short-side inner strapping — buffer 2 — robot loading — horizontal packing — long-side outer strapping — buffer 3 — short-side outer strapping — top film wrapping — perimeter film wrapping — unloading

[Centering Mechanism]

This component uses a motor-reducer to drive a chain transmission. After the push claw contacts the goods, the sensors on both sides of the push claw provide feedback signals. If the signal deviates significantly from the preset parameters for the goods, an alarm signal is triggered, and the parameters are then manually corrected to ensure that the glass stack is at the Target Position.

[Long-side Strapping Machine]

This component spans the conveyor line and automatically applies corner protectors and inner long-side strapping to the goods on the steel pallet, followed by outer long-side strapping.

[Short-side Strapping Machine]

This component is arranged on one side of the conveyor line and automatically performs inner short-side strapping on the goods on the steel pallet, followed by outer short-side strapping.

[Robot Station]

The robot places the side wood guard boards and top wood guard board at the set positions on the product. Fencing is installed around the station with a safety door; when the safety door is opened, the robot stops working to ensure safety.

[Horizontal Packing Machine]

This component spans the conveyor line. After the guard boards are placed, the horizontal frame lowers to perform horizontal strapping.

[Film Wrapping Machine]

This component uses a motor-reducer to drive a chain transmission, moving the film wrapping frame up and down. It can automatically adapt to the size according to the length of the goods, and a blade cuts the film after wrapping.

[Film Winding Machine]

This component wraps film around the goods on all sides. Fencing is installed around the winding machine with a safety door; when the safety door is opened, the machine stops working to ensure safety.

Current pain points

Most processes require manual operation and demand high professional skills from operators, resulting in persistently high labor costs. In addition, manual packing has relatively low efficiency, and incorrect placement can easily cause strapping machine threading failures, leading to considerable losses.

I/O module Application Mode

The equipment uses the PROFINET Protocol for communication. Signal acquisition, transmission and control are performed through 693000 Slice I/O Modules XB6-PN2002ST, XB6-3200B and XB6-0032B, which enable timely detection of errors during the packaging process and provide accurate compensation and correction. This achieves automatic packaging of stacked photovoltaic glass, greatly improving packaging efficiency while ensuring packaging consistency, reducing labor costs and minimizing packaging losses.

The Controller uses the XB6-0032B Digital output module to control the displacement of the hydraulic push plate in the glass stack centering device, so that the glass stack stops precisely at the transverse center position on the conveyor chain line. It also controls the Solenoid valve to drive the robot to automatically grip packaging materials and place them at the corresponding position on the glass stack for the subsequent packaging process.

The XB6-3200B Digital input module is used to collect position signals from multiple locations on the conveyor line (such as sensors on both sides of the push claw, proximity sensors, film marking sensors, etc.), enabling multi-point tracking and detection along the production line. When the deviation between the signal and the preset cargo parameters is too large, the system promptly issues an alarm signal. If the technical requirements are still not met after a preset number of tracking attempts, the system can automatically stop for inspection, preventing the production of defective products.

Product advantages

The 693000 XB6 series Slice remote I/O modules feature a small footprint, fast response, simple installation and Wiring, pluggable Terminal blocks, simple Configuration and stable Run. Through the above applications, they provide a stable and cost-effective solution for the automatic photovoltaic glass packaging line.

At present, 693000 has also launched a new generation of Slice I/O products, the XB6S series, which offers excellent interference resistance and ease of use. In addition, there are Integrated I/O Modules suitable for controlling scattered small-point signals, IO-Link Fieldbus I/O with IP67 protection rating, Fieldbus Valve Terminals and other products. This rich Product Series can meet the diverse and complex on-site needs of customers, delivering a better user experience.