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 · Batteries
Lithium battery module pack lines
This batteries application uses XBF distributed I/O to address field control, reliable communication and maintainable commissioning.
Solution architecture
The proposed architecture combines XBF distributed 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 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.
This content is based on the manufacturer’s published Lithium battery module pack lines application, adapted by ProControl while preserving its technical scope. View the official manufacturer source.