Market Application Background
In automotive wiring harnesses and components, tape wrapping is a common and important processing technique, mainly used for bundling, securing, and insulating wiring harnesses/components. Under the control of the wrapping head, the tape is evenly wrapped around the surface of the automotive wiring harness/component, and the system automatically cuts it after wrapping. There are three main types of automotive wiring harness tape wrapping methods:
With the rapid development of the automotive industry, the requirements for wiring harnesses and components in different functional parts are becoming increasingly stringent, which places higher demands on tape wrapping processes. Traditional manual tape wrapping or linear tape wrapping machines perform poorly in handling complex wrapping structures and diverse wrapping needs, making it difficult to effectively improve a company's output, efficiency, and quality.
To address these challenges, CNC systems have been gradually introduced into automotive tape wrapping machines. Through CNC numerical control commands, the machines can control the movements of the winding head, tape, and other components, ensuring efficient and uniform tape wrapping and enabling continuous operation over long periods.
Limitations of traditional winding methods:
Traditional tape wrapping solutions involve manual or linear tape wrapping machines.
• Manual wrapping: This method mainly relies on manual operation by workers who use hand-held wrapping tools to wrap tape around wire harnesses or parts. It is suitable for small-batch production, but due to its low precision, high workload, and low efficiency, it has been gradually phased out in large-scale production.
• Linear tape wrapping machine: This type of machine wraps tape around wire harnesses or components in a straight line using a fixed axis. The wrapping head typically moves only in one direction, making it suitable for wrapping simple, regular shapes. While it offers a high degree of automation, its performance is limited when handling products with many bends or requiring diverse wrapping patterns.
Positive motion technology solutions:
In response to existing market demands, Zhengdong has developed an open CNC application solution based on the VPLC532E automotive tape winding, which can achieve a smooth transition of product winding at corners and automatically generate winding parameters for products of different specifications through product trajectory teaching.
It supports setting different stacking ratios and can perform various winding methods by controlling the spindle speed and feed rate. When winding products at bends, the system can adaptively adjust the winding parameters according to the input strip width and feed rate while keeping the stacking ratio constant. This allows it to flexibly adapt to products of different specifications and shapes, improve production efficiency, and meet the needs of users for both large-volume and small-volume production.
It supports functions such as speed look-ahead and circular interpolation to ensure smooth motion trajectories at corners, optimize spindle speed and feed rate to improve product quality and throughput, and avoid problems existing in traditional adhesive wrapping processes. The system also supports secondary development based on the original system, allowing for customized interfaces and self-extended M-code.
01. VPLC532E in Open CNC Applications of Automotive Tape Winding
Traditional automotive tape wrapping solutions
• Batch production cycle time cannot keep up with the company's production needs
Products with many bends can only be processed manually.
Open CNC solution design for automotive tape wrapping
• 24DI: Connects to origin, limit, and other sensors, as well as switch signals, etc.
·12DO: High-speed output port connected to cylinders, etc.;
• EtherCAT interface: Connects to the EtherCAT bus driver to control the dual-drive gantry on the Y-axis, as well as the other 5 axes;
• LAN1 interface: Gigabit Ethernet port, for easy connection to the ZHD500X handheld box for teaching trajectory demonstration;
• 6-channel differential pulse axis interface: can be connected to stepper/pulse drivers.
Motion control implementation process
Point-to-point motion control is achieved using a pre-taught tape winding path. At bends, the system reduces the spindle speed and machining speed of each axis, and uses circular interpolation to achieve smooth winding at the bends by setting appropriate teaching points.
When the winding head reaches above and at the starting point, the system is paused using the M0 pause command in the NC file, awaiting manual loading and adhesive application. During processing, the system controls the opening and closing of the grippers and the lifting and lowering of the cylinders based on the real-time movement position of the X-axis.
After processing is completed, the system can perform single-axis or multi-axis segmented zeroing according to extended instructions, waiting for manual unloading.
Teaching process for automotive tape wrapping
▌Setting parameters
After entering the feed speed, stacking rate, and strip width, click "Update Parameters," and the system will automatically generate the parameters in the first two lines of the NC file.
▌Trajectory Teaching
Move above the starting point and click "Insert Node" to teach the trajectory. The system will automatically insert a line of G01 instructions.
▌Insert Pause
Clicking "Insert Pause" will automatically insert an M0 pause command, making it easier for manual loading operations.
Spindle Start
Move to the starting point and click "Spindle Start". The system will generate an M0 pause command and an M03 spindle start command to facilitate manual operation of the conveyor belt.
▌Corner Speed Adjustment
When you move to the front of the corner, you can click on [Speed Settings] to modify the spindle speed and feed rate at the corner to optimize the winding quality.
▌End of demonstration
After the teaching is complete, click "End Teaching". The system will automatically save the NC file and insert the M30 stop command.
▌Single-segment operation verification
Click "Next," and the system will run the program segment by segment starting from the line number where the cursor is currently located, facilitating step-by-step verification.
▌Optimized winding effect
The effect of the wrapping at the corner can be improved by adjusting the axis position and clicking "Update Coordinate Value" to modify the point coordinates in the NC file. Alternatively, the spindle speed and feed rate at the corner can be updated by modifying the speed settings to achieve the best wrapping effect.
Core advantages of the solution
• Standard CNC system: Adopts international standard CNC programming to achieve high-precision five-axis linkage machining;
• Facilitates independent development: Manufacturers can perform secondary development on the existing architecture to create custom-style interfaces and functions;
• Improved production efficiency: During the coating process, there is no need to wait for the cylinder to be triggered; the processing at the bends is completed by the system interpolation, reducing production downtime and improving overall efficiency.
• Simple teaching process: One-click insertion of teaching data facilitates NC file editing and allows for easy optimization and adjustment of the trajectory at any time;
• Automated winding: CNC tape winding systems automate the winding process, reducing human intervention and ensuring uniform and accurate tape winding;
• Reduce material waste: Precision winding minimizes material waste and optimizes resource utilization;
Suitable for mass production: Reduces reliance on manual operation, saving time, manpower and costs, making it suitable for mass production needs.
Solution Hardware Configuration
02. Introduction to Open Standard CNC Numerical Control System
The Open Standard CNC System is an internationally standardized CNC programming platform developed by Zheng Motion Company based on its ten years of accumulated CNC, CAM, and motion control technologies. Widely used in various CNC machining equipment, this system combines the flexibility of an open architecture with the stability of standardized programming, enabling it to meet complex CNC machining tasks. The system supports multi-axis linkage control, making it particularly suitable for machining complex-shaped parts and controlling automated production lines.
This system aims to provide users with CNC development needs with a powerful software and hardware platform, reducing the difficulty and development cycle of CNC development, reducing the risk of customer projects, and improving development efficiency.
Introduction to the Functions of Open Standard CNC Numerical Control System
CNC
It features a fully independently developed CNC core, international standard CNC programming, and supports switching between Chinese and English interfaces.
RTHMI
The software features fully independently developed graphical interface configuration modules, and the development platform has a built-in complete CNC HMI interface, facilitating rapid development for users.
RTCAD
The fully independently developed CAD drawing to CAM conversion module reads CAD drawings and converts them into machining G-code.
RTVision
The fully independently developed vision function module measures, corrects deviations, and reads barcode and QR code information, and interfaces with EMS.
