Application requirements
I/O density, cycle time, motion or process requirements, field distances and maintenance needs are assessed together. This defines the requirements of the working system, not just individual products.
Solidot · Machining
Aluminum drawing machines
This machining application uses XB6S modular remote I/O to address field control, reliable communication and maintainable commissioning.
Solution architecture
The proposed architecture combines XB6S modular remote I/O with the machine’s existing control infrastructure and communication protocols. Final product and module selection depends on site requirements.
How can ProControl help?
ProControl can adapt the solution to local project requirements in Türkiye, from site assessment, I/O planning and protocol selection to panel layout, commissioning and after-sales support.
Official application content
Technical details, tables and application images
The technical workflow and visual information from the manufacturer are presented below.
The aluminum drawing machine is a critical equipment in aluminum processing, responsible for uniformly pulling aluminum profiles from extruders to ensure dimensional accuracy and surface quality. With increasing industry demands for automation and intelligence, these machines require precise speed control, tension adjustment, and multi-device coordination during operation, placing higher demands on the real-time performance and stability of control systems. By implementing remote I/O technology, aluminum drawing machines achieve seamless signal acquisition, equipment synchronization, and process parameter optimization, helping enterprises enhance production efficiency and product quality to meet the high standards of modern aluminum processing.
Solidot products used in this case:
XB6S-EI2002 , XB6S-1616B , XB6S-0016B , XB6S-0032B , XB6S-C01SP
I. Production Process Overview
Core Workflow of Intelligent Aluminum Drawing Machine: Preparation → Operation Monitoring → Winding Adjustment → Finished Product Output
Preparation: Operators configure material specifications, drawing speed, and inverter parameters via HMI to initialize equipment, ensuring precise positioning of aluminum coils at the drawing inlet.
Operation Monitoring: Real-time monitoring of key parameters (drawing speed, motor current, material tension) with closed-loop control for dynamic adjustment, preventing deformation or breakage to ensure continuous production.
Winding Adjustment: Dynamic regulation of winding speed and tension based on material length and changes in winding diameter, ensuring uniform coiling while preventing quality issues from loosening or overtightening.
Finished Product Output: After drawing completion, profiles are smoothly transferred via conveyor to the next process, with production data recorded for quality traceability and process optimization.
II. I/O Module Implementation
Using EtherNet/IP protocol, Solidot modules—digital I/O module XB6S-1616B , digital output modules XB6S-0016B / XB6S-0032B , and serial communication module XB6S-C01SP —connect to Rockwell 1769-series PLC via coupler XB6S-EI2002 .
- Digital Input Module (XB6S): Collects emergency stop status, limit switch signals (drawing stroke protection), tension sensor threshold alarms, and proximity switch signals (coil positioning detection). Its NPN/PNP compatibility supports diverse sensor types, ensuring flexible and stable signal acquisition.
- Digital Output Module: Controls hydraulic lifting platform positioning, lubrication system solenoid valves, auxiliary conveyor rollers, drawing motors, cooling fans, alarm indicators, winding motor drivers, flying shear solenoid valves, and conveyor motors.
- XB6S-C01SP : Reads power meter parameters in real-time and executes PLC control commands. Collectively enabling precise drawing speed regulation for consistent, stable aluminum profile handling.
III. Solution Comparison
The client’s original bus solution suffered from complex decentralized wiring, low multi-device coordination efficiency, and significant drawing speed fluctuations. Additionally, weak EMI immunity in some modules caused high signal packet loss rates, frequently triggering production issues like roller slippage or material deformation.
After adopting Solidot’s Slice Remote I/O XB6S series:
- Enhanced transmission efficiency and EMI resistance
- Noticeably improved drawing speed control precision
- Reduced tension errors in closed-loop adjustments
- Significant improvement in aluminum surface quality
- Mixed I/O configuration reduces wiring complexity
IV. High-Reliability Slice Remote I/O Series: XB6S
Solidot’s XB6S Slice Remote I/O series supports multiple bus protocols and integrates motion control/temperature acquisition modules. Key features include:
- Rigorous EMC testing for superior interference resistance and zero disconnections
- Diagnostic/alarm functions with anomaly logging for intelligent feedback
- User-friendly design with simplified maintenance
This content is based on the manufacturer’s published Aluminum drawing machines application, adapted by ProControl while preserving its technical scope. View the official manufacturer source.