Decowell's products are widely used in various links of automobile manufacturing, and of course, they are also suitable for the production and 

manufacturing of heavy-duty vehicles.

These "big guys" in the automotive industry actually need the strong support of the small Decowell EX series products? Let's take a look!

01 Industry analysis

Automobile assembly plants are generally divided into four major workshops: stamping, welding, painting, and assembly.

The painting production line is an important part of it. This production has a strong professionalism and basic nature, and its production quality 

directly affects the overall production quality and efficiency of the automobile. In order to comprehensively improve the production efficiency of 

automobile painting production lines, electrical automation control systems have been widely used.

02 Process description

The painting workshop is benchmarked against passenger car processes and is equipped with pre-treatment electrophoresis lines, electrophoresis 

polishing lines, body sealing lines, mid-coat spraying lines, topcoat spraying lines, and finishing polishing lines.

The pre-treatment electrophoresis adopts the silicon + electrophoresis process, which meets product quality and environmental protection 

requirements at the same time, and use flip conveying equipment to ensure that the electrophoretic paint film has no liquid and air chamber 

problems.

The body sealing line is equipped with a glue-spraying robot to realize the automation of body glue-spraying; the middle and topcoats adopt 

the 3C2B production process, equipped with external spraying robots, internal spraying robots, and door-opening robots to realize unmanned 

automatic spraying.

The painting workshop also has a laboratory and is equipped with corresponding testing and detection instruments to ensure consistency 

of process parameters and product quality.

03 Pain points on site

Considering that the production line of the heavy truck painting workshop requires a large space, the painting line requires lighting management 

that realizes the lighting of the painting system and the overall building lighting control system at the same time.

At the same time, in the painting workshop, because the middle coating adopts separate drying and polishing, there are certain requirements for 

environmental temperature control.

In short, the coating production line has higher requirements for the accuracy of data collection and the stability of equipment, and Decowell 

products are required to meet the following requirements:

Support Profinet remote I/O;

Support access to analog input and output;

Due to the safety standards of the lighting system, it is necessary to support the MRP function;

Centralized collection of external signals, and the overall response time is not less than 10ms;

The equipment in the cabinet needs to save space as much as possible;

04 Decowell Solution

In the heavy truck coating process, Decowell EX series card-type I/O is trusted by many customers for its excellent technical parameters and 

excellent product quality.

Master station: Siemens 1500 series

Applicable process section: electrophoresis, coating

Project I/O configuration: about 200 digital points for the entire line

Decowell application advantages: stable slave communication, high analog precision, and stable signal.

Project Overview: This project is a large domestic heavy truck production base, which applies the painting process section in the body-in-white 

workshop. In this process, all lighting systems in the workshop are controlled by EX digital input and output modules.

The EX analog module achieves precise temperature control by controlling the frequency converter to ensure that the intermediate coating 

operation meets the process standards. Our company's EX-4454 (4-20mA) is connected to the Siemens PLC to reflect the real-time temperature 

signal in the painting workshop.

At the same time, according to the signal, the PLC will perform real-time temperature correction. If the temperature is higher or lower than the 

set range, it will drive the frequency converter through the analog output module 5414 (4-20mA) to drive the temperature control fan, and 

deliver cold air or exhaust hot air as needed, to achieve precise temperature control and real-time temperature control on-site needs.

05 Decowell EX series card I/O

Product features:

1. Stable communication, fast response, convenient operation, and high efficiency;

2. Rich bus protocols, supporting multiple communication protocols, such as EtherCAT, PROFINET, DeviceNet, CC-Link, Ethernet/IP, 

Modbus-RTU, CC-Link IEF Basic, etc.;

3. Rich signal types, which can meet factory automation and process automation control. Support digital quantity, analog quantity, 

temperature module, encoder module, free communication module;

4. Compact structure, small module size, a single I/O module supports up to 32 digital signal points;

5. Strong expansion capability, a single adapter can expand up to 32 I/O modules, and the coupler scans quickly;

6. Simple and easy to use, standard DIN35 rail installation, plug-in terminals, and tool-free installation.