According to statistics, the amount of PCBs used in new energy vehicles will be 5-8 times that of traditional vehicles. The market for automotive PCBs (hereinafter referred to as automotive boards) will grow rapidly as the penetration rate of new energy vehicles increases.
Automotive sheet metal products vary in length, with the longest being approximately 1.2 meters . If soldering or welding is done at a single workstation, not only is the load heavy, but single-line processing is also inefficient. To meet the demands of rapid production, multi-workstation collaborative processing is required.
Most EtherCAT bus control products on the market nowadays have bus-to-pulse conversion solutions, along with a certain number of encoder feedback and high-speed I/O . However, very few can meet the requirements of multi-station simultaneous operation for automotive board soldering or tinning. From an economic perspective, whether using high-end foreign brands or multiple bus-to-pulse junction boxes, the need to meet the requirements of high-speed I/O and encoder feedback leads to the waste of other resources, thus increasing costs.
ZW3C collaborated closely with system integrators to achieve a customized solution that rationally combines EtherCAT control and pulse control modes, providing an efficient approach for automotive sheet metal processing. The wiring diagram is shown below:
Resource allocation and functional characteristics of the control components of each piece of equipment in the entire production line:
In the project, the ADT-6320E-C is Zowell's EtherCAT master station motion control card, and the ADT-9180-C is a matching single-ended digital control expansion board. The customized functions and performance requirements are compact and fully meet the customer's multiple requirements.
❶ Supports 4- channel interpolation groups, providing parallel support for multiple workstations;
❷ The 8- channel high-speed output port ( maximum frequency 1MHz) enables ultra-fast response and high-speed position comparison triggering for tinning, soldering, and other applications.
❸ Eight encoder inputs ( maximum frequency 4MHz) provide high-precision encoder position assurance for high-speed position comparison ( including gantry frequency divider input ) ;
❹ The expansion board comes with 42 optocoupler-isolated digital inputs and 26 optocoupler-isolated digital outputs, completely replacing the EtherCAT bus IO module, offering higher response speed while saving cost and installation space.
Meanwhile, the Zowell ADT-6320E-C product also excels in applications such as automotive panel irregular-shaped component insertion, AOI mobile phone 3D inspection, and laser welding, offering universal functions and performance applicable to various industries.
• 16/32/64 -node control, supports multiple EtherCAT protocol bus single / dual axis drives, and is even more suitable for combination with Zowell QXE bus servo drives;
• Supports speed look-ahead, linear interpolation, 2D/3D circular interpolation, up to 10,000 interpolation buffers and 1,000 buffered I/O events, handling diverse trajectories with ease.
Currently, Zowell's customized bus motion control solutions have been adopted by many mid-to-high-end customers. By providing " one-stop " service, Zowell has won customer praise and expanded the application areas of its products.
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