Customer Background
The Client Is A Taiwan-Based Connector Manufacturer Specializing In Precision Assembly With Automated Multi-Station Production Lines
Due To High Production Speed, Frequent I/O Signal Interaction Between Devices Requires Stable And Real-Time Communication, Especially In Coordinated Control Scenarios
Problems
During Operation, The Client Experienced The Following Issues:
Signal Delay Under High-Speed Production Conditions
Occasional Synchronization Issues Between Stations
Complex System Modification When Adding New Equipment
Difficulty In Troubleshooting Communication Faults
Result: Unstable Production Rhythm And Reduced Coordination Efficiency
Solution (With Specifications)
A Distributed Ethercat-Based I/O System Was Implemented To Optimize The Existing Communication Structure
Configuration Includes:
Communication Module: Ex-1100 Ethercat Network Adapter
Input Module: Ex-203S (32-Channel Di)
Output Module: Ex-303S (32-Channel Do)
Terminal Module: Ex-Ter01
Key Technical Improvements:
Real-Time Ethercat Communication For Synchronized Updates
Unified Communication Architecture To Reduce Delay
Modular Design For Easy Expansion
Improved Stability And Interference Resistance
Specifications:
Protocol: Ethercat
Di: 32 Channels
Do: 32 Channels
Network Module: Ex-1100
Weight: 1.18 Kg
Package Size: 42×27×22 Cm
Customer Feedback
After System Implementation, The Client Reported:
Smoother Coordination Between Devices
Improved Signal Stability Under High Load
More Consistent Production Rhythm
Easier Troubleshooting For Maintenance Teams
Overall Result: Improved System Control And Coordination Efficiency
Conclusion
In High-Speed Automation Environments, Communication Architecture Plays A Critical Role In System Stability
This Case Demonstrates That Upgrading To A Real-Time Ethercat System Significantly Improves Synchronization And Scalability
The solution has been applied in the consumer electronics manufacturing industry, especially in high-speed, multi-station automation environments.
