Airtightness testing is a critical quality control process in automotive manufacturing, ensuring the integrity and reliability of vehicle systems. This testing is essential for components such as fuel systems, air conditioning units, brake systems, and engine assemblies. High-precision leak detection equipment utilizing pressure decay and flow measurement methods validates the sealing performance of axles, automotive parts, and other sealed components, preventing potential failures and ensuring vehicle safety and performance standards.

The client's existing airtightness testing equipment faced several operational challenges:

The system primarily utilized airtightness testing equipment including high-precision leak detection instruments (pressure/flow measurement methods) for applications in axles, automotive components, and sealing performance testing.

PROFINET was employed for system communication.

A complete Western-brand suite was implemented.

(1) Excessive Electrical Cabinet Space Requirements

• Western-brand I/O modules and expansion cabinets occupied excessive internal cabinet space
• Customer required independent I/O module cabinet placement with specific protection requirements

(2) Module Selection Complexity and Long Lead Times

• Western-brand I/O modules varied significantly in functionality across different module types
• Selection process was cumbersome with extended delivery periods

I/O Configuration: Total of 40 analog input/output points

• Model: PN2-4AI4AO*5 (5 modules)

The DECOWELL solution utilizes the RS series modules with IP40 protection rating, enabling independent cabinet placement outside the main electrical cabinet, significantly reducing cabinet footprint.

The RS series analog modules support flexible input and output configurations. Current and voltage ranges can be selected through DIP switch settings via BoGuan static configuration, eliminating the need for complex module type selection and simplifying procurement.

The solution employs RS series modules with European-style terminal blocks:

• Three-in-one European terminal design
• E-con connector with three connection methods
• Modular quick-plug sensor supply capability
• Reduced on-site wiring costs
• High analog precision (16-bit resolution)
• Strong stability
• Hot-swap capability without equipment shutdown
• Self-diagnostic functionality
• Low maintenance costs

• Communication Protocol: PROFINET industrial Ethernet
• I/O Modules: DECOWELL PN2-4AI4AO (5 units)
• Total I/O Points: 40 analog input/output channels
• Protection Rating: IP40 for flexible installation
• Resolution: 16-bit high-precision analog conversion

1. Space Optimization

• Compact module design reduces cabinet footprint by up to 40%
• IP40-rated modules enable flexible distributed installation outside main cabinets

2. Simplified Configuration

• DIP switch-based range selection eliminates module variety complexity
• Reduced procurement lead times and inventory requirements
• No need to select different module types for different functions

3. Enhanced Reliability

• 16-bit resolution ensures precise measurement accuracy
• Hot-swap capability minimizes production downtime
• Built-in diagnostics enable proactive maintenance
• Strong stability for continuous operation

4. Cost Efficiency

• Reduced wiring complexity lowers installation costs
• Three-in-one terminal design and E-con connectors simplify field wiring
• Modular design simplifies spare parts management
• Lower total cost of ownership compared to traditional solutions

The images showcase the airtightness testing equipment with the integrated DECOWELL automation system. The left image displays the testing station with precision leak detection apparatus and automated handling mechanisms. The right image reveals the compact electrical cabinet interior featuring the RS series I/O modules with organized wiring, demonstrating efficient space utilization and professional installation standards.

The DECOWELL automation solution has delivered measurable improvements:

• 40% reduction in electrical cabinet space through compact module design and IP40-rated external mounting capability
• Simplified procurement process with universal analog modules featuring DIP switch configuration
• Enhanced system flexibility via hot-swap and modular configuration
• Improved measurement precision with 16-bit analog resolution
• Reduced installation time and costs through optimized wiring solutions (European terminals and E-con connectors)
• Increased system reliability with built-in diagnostics and stable performance
• Lower maintenance costs through self-diagnostic functionality and hot-swap capability

This implementation demonstrates DECOWELL's capability to provide tailored automation solutions that address specific customer challenges while maintaining high performance standards in critical automotive quality control applications.

About DECOWELL Automation

DECOWELL specializes in industrial automation solutions for the automotive manufacturing sector, offering high-performance I/O systems, PLC integration, and custom control solutions. Our RS series modules are designed to meet the demanding requirements of automotive testing and production environments while optimizing space, cost, and operational efficiency.