Функциональный дизайн и изготовление жгута проводки сервопривод

Производство жгутов для сервоприводов включает в себя создание специализированных жгутов проводов для точного позиционирования и перемещения., прежде всего в промышленной автоматизации. Эти жгуты, часто используется с серводвигателями, обеспечить контролируемые электрические соединения для приводов, обеспечение точных и повторяемых действий. В производстве, Жгуты сервоприводов собираются путем разрезания, раздевать, обжимка, пайка, и прокладываем провода, часто с автоматизированным оборудованием для повышения эффективности и качества.

Прямоугольная кабельная сборка 2 Socket to Socket 0.984′ (300.00мм, 11.81″)

Прямоугольная кабельная сборка 16 Socket to Socket 0.500′ (152.40мм, 6.00″ )

Комплект жгутов проводов сервопривода с компонентами мультиплексного разъема

The functional design and manufacturing of servo harnesses are the core links to ensure the stable operation of industrial automation equipment. Its technical requirements cover multi-dimensional indicators such as electrical performance, mechanical strength and environmental adaptability. The following is an analysis of key points:
я. Key points of functional design
‌Signal and power transmission architecture‌:
Use multi-strand tinned copper wire conductors to improve the conductivity efficiency, and ensure that the wire diameter and cross-sectional area match the power requirements of the equipment;
Optimize high-frequency signal transmission through twisted pair or coaxial structure to reduce signal delay and distortion.

‌Anti-interference structure design‌:
Built-in metal braided layer or aluminum foil shielding layer to suppress the impact of electromagnetic interference (Эми) on signal transmission;
Differential signal transmission technology enhances common mode noise suppression capability and is suitable for precision control systems.

Design and Planning:
Wire lengths, connector types, and routing paths are determined based on the application requirements.
Material Preparation:
Wires are cut and stripped to the correct lengths and insulation layers are removed.
Termination:
Terminals or connectors are attached to the wire ends using methods like crimping or soldering.
Harness Assembly:
Wires are bundled and routed according to the design, often using automated systems for tasks like cutting, раздевать, and routing.
Quality Control:
Harnesses are tested to ensure proper connections and functionality, with automated testing systems improving consistency.

Кастомизация:
Wire harnesses can be tailored to specific applications, with variations in wire gauge, insulation, and connector types.

Functional Applications:
Servo harnesses are used in a wide range of applications where precise control and repeatability are crucial, включая:
Industrial Automation:
Used to control robots, automated assembly lines, and other machinery.

Robotics:
Provide power and control signals to robotic arms and other robotic components.

Автомобиль:
Used in vehicles for controlling actuators like brakes, steering, and other systems.

Аэрокосмическая промышленность:
Used in aircraft control systems and other applications requiring precise movement.

Other Applications:
Found in medical devices, CNC machines, and other applications requiring controlled movement.
Key Features and Benefits:
Precision and Accuracy: Servo harnesses enable precise control of actuators, ensuring accurate positioning and movement.
Надежность: Used in demanding applications where reliability is critical.
Efficiency: Automated manufacturing processes and specialized equipment improve efficiency and reduce production costs.
Кастомизация: Can be tailored to meet specific application requirements.
Space Optimization: Efficient routing of wires and cables within the harness allows for optimal use of available space.

‌Dynamic mechanical performance adaptation‌:
Highly flexible sheath materials (such as TPU/PUR) achieve more than 10 million drag chain cycle life, suitable for high-frequency motion scenarios such as robot joints;
Multi-layer twisted conductor structure improves bending fatigue resistance, and the bending radius can reach 6 times the wire diameter.

Iii. Manufacturing process flow
‌Raw material control‌:
Conductors are made of oxygen-free copper (OFC) to ensure conductivity ≥ 98%, and the sheath material has passed the VW-1 flame retardant certification;
The terminal plating adopts a gold/silver composite process, and the contact resistance is ≤ 5mΩ.
‌Precision processing links‌:
The CNC wire cutting accuracy is controlled within ±0.5mm, and the laser wire stripping avoids damage to the conductor cross section;
The pressure range of the pneumatic crimping equipment is 20-50N·m, and the crimping height tolerance is ±0.03mm.
‌Quality verification system‌:
Execute IEC 60332-1 vertical combustion test, IP67 protection level verification and 10G vibration test;
100% online conduction test, insulation resistance ≥ 100MΩ/km (500VDC).

Iii. Special scenario solutions
‌New energy application‌:
The 600V withstand voltage design is combined with double-layer silicone insulation to adapt to the high current working conditions of electric vehicles. ‌High-precision equipment integration‌:
Miniaturized connectors (M8/M12) integrate power + signal composite transmission, saving 70% of installation space;
Development trends in this field include: conductor nano-coating technology to improve wear resistance, optical fiber composite transmission structure to enhance bandwidth, AI-driven intelligent detection system to reduce defective rate, и т. д..