The application of Solidot's remote Slice I/O module XB6S in the automotive manufacturing stamping station

In automotive manufacturing, the stamping station plays a vital role: it mainly performs stamping and forming on metal sheets to produce various body-in-white components. Stamping stations generally use one of three methods — progressive die stamping, multi-station stamping, or tandem stamping — each applied to the production of different automotive sheet metal parts due to its respective characteristics. With the rapid development of the automotive industry, stamping stations are becoming increasingly automated, placing higher demands on the performance and reliability of the automation control system.

The Solidot products used in this case study: XB6S-PN2002, XB6S-3200, XB6S-0032B, XB6S-0016B, etc.

1. Production process overview

The stamping station in this case study uses the multi-station stamping method, which combines multiple stamping operations — such as drawing, punching, and flanging — on a single press. Its process flow mainly consists of the following stages:

[Preparation stage]

Place the metal sheet in the designated position, ensuring it is flat, free of scratches and contamination, and check that the die is correctly installed and the press is in good condition.

[Loading]

The automatic loading device feeds the metal sheet accurately into the press die. The loading device must have high-precision positioning capability to ensure the sheet is positioned correctly in the die.

[Stamping]

The press performs stamping and forming on the metal sheet according to the preset program and pressure parameters. In this process, the die design and press control are critical — they directly determine the quality and accuracy of the stamped part.

[Unloading]

After stamping is complete, the automatic unloading device removes the formed part from the die and places it on a conveyor belt, ready for the next process. The unloading device must have sufficient force and precision to avoid damaging the part.

2. I/O module application mode

The Solidot XB6S series remote I/O modules solve the problems of complex wiring, communication interference, and difficult fault location at automotive stamping stations. The modules' distinctive structural design simplifies wiring for multi-station equipment, saving cable and labor costs. The modules themselves offer excellent interference immunity, ensuring stable communication. They also feature automatic diagnostics, alarms, and exception logging, enabling rapid fault localization for easy troubleshooting and maintenance.

This case study uses the PROFINET bus protocol. The PLC connects via the PROFINET coupler XB6S-PN2002 to XB6S digital input module XB6S-3200, digital output module XB6S-0032B, XB6S-0016B, and other modules, achieving high-speed and accurate data exchange.

In the loading stage, the XB6S-3200 acquires sensor signals to determine whether the sheet is in position. In the stamping stage, the XB6S-0032B follows control system commands to assist in controlling the press motion, ensuring stamping stability. In the unloading stage, the XB6S-0016B likewise follows control system commands, transmitting signals to drive the unloading device for automatic removal of the formed parts.

3. High-reliability remote I/O module XB6S series

The Solidot XB6S series remote I/O modules support multiple bus protocols and include function modules for motion control and temperature acquisition. The products have passed strict EMC testing, offer superior interference immunity, and eliminate disconnections. They support diagnostics, alarms, and exception logging, providing intelligent feedback and convenient operation.