This approved battery-formation case used RB analog input/output modules across eight PROFINET stations for high-channel-count measurement and setpoint control. The reported accuracy, yield and savings are project-specific case results and must not be treated as general RB product guarantees without the project's calibration and validation conditions.
16-bit analog I/O modules enable ±0.1% accuracy in lithium battery formation charging
Challenge
The line required simultaneous analog measurement and traceability across 512 formation channels, with tighter accuracy than the previous system.
Solution
RB analog input/output modules were distributed across PROFINET stations and connected to the customer's MES traceability workflow.
Implementation
128 RB-AI04 and 64 RB-AO04 modules were deployed across 8 RB-COUPLER-PN stations. PROFINET RT communication delivered 1ms cycle times for all 512 analog channels. The analog data was streamed to the customer's MES via OPC UA for cell-level traceability. The hot-swap capability allowed module replacement during production without stopping the formation process.
Results
“The 16-bit resolution and ±0.1% accuracy were non-negotiable for our formation process. Decowell delivered both, and the hot-swap capability means we never have to stop the line for maintenance.”