Solidot · Packaging

Filling and weighing systems

This packaging application uses XB6S modular remote I/O to address field control, reliable communication and maintainable commissioning.

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.

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.

Filling and weighing systems are critical equipment in industries such as food and chemicals, responsible for quantitative liquid filling. With rising demands for production efficiency and precision, these systems require rapid start-stop control, real-time weight acquisition, multi-valve coordination, and full-process monitoring, imposing stringent requirements on real-time response and signal stability of control systems. The adoption of Solidot's XB6S Remote I/O Modules effectively simplifies wiring, laying the foundation for stable and efficient filling.

Products Used in This Case

XB6S-PN2002

XB6S-1600 , XB6S-3200 , XB6S-0012J/6

XB6S-A40I , XB6S-A80I , XB6S-A04I , XB6S-A08I

XB6S-A40TM , XB6S-A80TM , XB6S-C01SP

Manufacturer application image — Official manufacturer application image

PART ONE: Production Process Overview

Filling Workflow : Empty Can Positioning → Filling Execution → Weighing Regulation → Full Can Detection/Label Printing

Empty Can Positioning : Conveyor transports cans to stations; proximity switches detect positioning signals to trigger clamping mechanisms.
Filling Execution : Controls conveyor speed/start-stop, sequences main/fine-tuning valves based on preset volumes for rapid filling and precision replenishment.
Weighing Regulation : Load cells acquire weight in real-time; system dynamically adjusts valve actions to ensure accuracy.
Full Can Detection/Label Printing : Valves close upon reaching target weight; confirms fill integrity, releases clamps after leak check, and prints traceability labels.

PART TWO: I/O Module Implementation

PROFINET bus protocol with Siemens S7-1500 PLC as master. Coupler XB6S-PN2002 connects:

Digital Input （ XB6S-3200 、 XB6S-1600 ） : Captures can-positioning, valve limits, E-stop, and safety door signals.

Relay Output （ XB6S-0012J/6 ） : Controls motor start-stop, valve actuation, and alarm signals.

Analog Modules （ XB6S-A40I 、 XB6S-A80I 、 XB6S-A04I 、 XB6S-A08I ） : Transmits multi-station weight sensor/valve current signals with anti-interference stability.

Temperature Modules （ XB6S-A40TM 、 XB6S-A80TM ） : Monitors material temperature and critical equipment hotspots.

Serial Module （ XB6S-C01SP ） : Connects label printers via RS485.

PART THREE: Optimization Results

Solidot’s XB6S Remote I/O Modules enabled:

Analog modules acquire weight signals locally with high anti-interference accuracy.
Simplified wiring enhances maintainability.
Slice I/O design allows on-demand expansion, reducing upgrade costs and commissioning time.

PART FOUR: XB6S Series Highlights

Supports multiple bus protocols with motion control/temperature acquisition modules.
Passes rigorous EMC tests with superior noise immunity and zero disconnections.
Diagnostics, alarms, and exception logs enable smart feedback and ease of use.

This content is based on the manufacturer’s published Filling and weighing systems application, adapted by ProControl while preserving its technical scope. View the official manufacturer source.