1. Usinage pré-CNC: Design and Preparation for Electric Curtain Prototypes
Avant de lancer Usinage CNC for the electric curtain prototype, Un stade de conception et de préparation systématique est essentiel pour répondre, de construction, et les exigences de l'expérience utilisateur. Cette étape suit une séquence linéaire, avec des détails clés organisés dans le tableau ci-dessous.
| Étape de conception | Exigences clés | Matériaux recommandés |
| Analyse de la demande de produits | Core functions: Smooth curtain opening/closing (speed 5-10cm/s), forward/reverse rotation, limit position control; Exigences structurelles: Track load-bearing capacity (≥2kg), drive mechanism torque (≥0.5N·m), curtain body compatibility (cloth/PVC soft curtain); Apparence: Hidden screws, matte track surface (réduit la réflexion de la lumière); Reserve space for motor, gear set, PCB control module, and power interface (DC 12V). | – |
| 3D Modélisation & Conception structurelle | Utiliser le logiciel CAO (Solide, Et nx) Pour créer des modèles 3D avec précision (tolérance ± 0,05 mm); Design components: track (straight/curved), motor mount, gear box, curtain fixing clips, and control box; Optimize track inner teeth (module 0.5-1, tooth pitch accuracy ±0.02mm) for smooth meshing; Add stiffeners to track (épaisseur 1,5-2 mm) to avoid deformation under load. | – |
| Sélection des matériaux | Choisissez des matériaux en fonction de la fonction des composants, machinabilité, et durabilité, tout en répondant aux normes de production de masse. | Track/Gear Box: Alliage en aluminium 6061/6063 (léger, à l'usure, épaisseur 2-3mm); Motor Mount/Control Box: Alliage ABS/PC (faible coût, isolation, épaisseur 1,5-2 mm); Engrenages: Copper/steel (couple élevé, à l'usure) or POM plastic (frottement faible, faible bruit); Curtain Fixing Clips: Nylon (léger, résistant à la corrosion). |
| Prétraitement des matériaux | Couper les matières premières en flans (laisser une surépaisseur d'usinage de 0,5 à 1 mm): Alliage en aluminium via la scie à bande, ABS/POM via laser cutting; Alliage d'aluminium recuit (300-350° C pour 1-2 heures) Pour réduire le stress interne; Dry ABS/POM (80-100° C pour 2-3 heures) Pour éliminer l'humidité (Empêche les bulles d'usinage); Nettoyez tous les blancs avec de l'alcool pour enlever l'huile et la poussière. | – |
2. CNC Machining Preparation for Electric Curtain Prototypes
Préparation adéquate avant l'usinage formel assure l'efficacité et la précision Usinage CNC for electric curtain prototypes. Cette section couvre la sélection des outils, programmation, et conception de luminaire.
2.1 Sélection des matériaux et des outils
Le choix des matériaux et des outils affecte directement la qualité et l'efficacité de l'usinage. Le tableau ci-dessous fournit des recommandations détaillées:
| Catégorie | Options spécifiques | Scénarios d'application |
| Structural Materials | Alliage en aluminium 6061 plaque (2-3MM), Abs / plaque PC (1.5-2MM), POM rod (diameter 8-12mm) | Aluminum alloy for tracks/gear boxes (chargé de chargement); ABS/PC for control boxes (isolation); POM for gears (frottement faible). |
| Transmission Materials | Copper rod (diameter 5-8mm), steel sheet (1-1.5MM) | Copper for high-torque gears; steel for gear shafts (à l'usure). |
| Outils d'usinage rugueux | Φ8-12 mm Cutter à fond plat (alliage d'aluminium / abdos), Φ6-8 mm Cutter à fond plat (Pom) | Élimination rapide des matériaux pour les grands composants (tracks, control boxes). |
| Outils de finition | Φ2-4mm ball-head cutter (track inner teeth), Φ1-2mm Cutter de calcul des racines (gear grooves), Φ3-5mm drill bit (trous de montage) | Ensure precise details (track teeth, gear profiles) et surfaces lisses (RA0.8-RA3.2). |
| Outils spéciaux | M3-M5 taps (trous filetés), gear milling cutter (module 0.5-1), frappeur de filetage (gros trous) | Process assembly threads and gear teeth (ensure meshing accuracy). |
2.2 Programmation et conception de luminaires
La programmation scientifique et les appareils stables empêchent les erreurs d'usinage et assurent la précision.
| Lien | Opérations clés | But & Effet |
| Programmation de came | – Usinage sous-zone: First process track outer contour, then inner teeth; Machine gear box cavity before assembling with gears to avoid interference.- Coupure en couches: Régler la profondeur de brouillage de 0,5 mm (alliage d'aluminium / abdos) ou 0,2 mm (Pom); profondeur de finition 0,1-0,2 mm.- Spiral interpolation: Use for track inner teeth (ensures tooth profile accuracy ±0.02mm) and gear grooves. | Améliorer l'efficacité; Assurer une précision dimensionnelle (± 0,05 mm) and smooth gear meshing. |
| Conception de luminaire | – Aluminum alloy tracks: Use precision clamps with rubber pads (prevent deformation); for long tracks (≥1m), use multi-point support fixtures.- Gears/POM parts: Use vacuum adsorption platform (même la pression, no damage); for small gears, use custom jigs for synchronous clamping.- Arbres de vitesses: Utilisez le mandrin à trois mâchoires pour tourner (ensure coaxiality ≤0.03mm). | Maintenir la stabilité de la pièce; Évitez les dommages de la surface et la déviation dimensionnelle. |
3. Core CNC Machining Process for Electric Curtain Prototypes
Le formel Processus d'usinage CNC transforme les modèles de conception en parties physiques, with strict control over each step to ensure functionality and durability.
3.1 Usinage des composants principaux
Différents composants nécessitent des étapes d'usinage ciblées, comme détaillé ci-dessous:
| Composant | Étapes de brouillage | Étapes de finition |
| Track (Alliage en aluminium) | 1. Contour extérieur de l'usine (length 1000-1500mm, width 20-30mm, conserver une allocation de 0,5 mm);2. Mill inner cavity (depth 10-15mm) for gear movement;3. Drill mounting holes (Φ4mm, spacing 200mm) on track sides. | 1. Machine inner teeth (module 0.8, tooth depth 2mm) via spiral interpolation;2. Chamfer track edges (C0,5mm) pour éviter la netteté;3. Polish inner cavity walls (Ra1.6) for smooth gear movement. |
| Gear Box (ABS/PC) | 1. Forme extérieure du moulin (80×50×30mm, conserver une allocation de 0,5 mm);2. Mill motor mounting hole (Φ20mm) and gear cavity (matches gear size);3. Cut wire slots (width 3mm) for control module wiring. | 1. Parois creuses lisses (Ra3.2) to reduce gear friction;2. Tap M3 threaded holes (for motor fixation);3. Deburr wire slots to prevent cable damage. |
| Engrenage (POM/Copper) | 1. Turn rod into cylindrical blank (diameter matches gear outer diameter, conserver une marge de 0,3 mm);2. Mill gear blank thickness (5-8MM);3. Rough mill gear teeth (module 0.5-1, leave 0.1mm finishing allowance). | 1. Finish mill gear teeth (tooth profile accuracy ±0.02mm);2. Polish gear surface (Ra0.8) to reduce noise;3. Machine keyway (width 2mm) for shaft connection. |
| Control Box (Abs) | 1. Mill box shape (100×60×40mm, conserver une allocation de 0,5 mm);2. Mill PCB cavity (depth 8-10mm) and power interface cutout (DC 12V size);3. Percer des boutonnières (Φ5mm) for control switches. | 1. Parois creuses lisses (Ra3.2);2. Chamfer button holes (C0.3mm) for easy switch installation;3. Tap M3 threaded holes (for box cover assembly). |
3.2 Usinage des détails clés
Critical details directly affect the prototype’s functionality and user experience:
- Track Inner Teeth Machining: Use gear milling cutter with spiral interpolation to ensure tooth pitch accuracy (± 0,02 mm) and meshing clearance (0.1-0.2MM); Test with gear blank to avoid jamming.
- Motor Mount Machining: Machine positioning stop (height 3mm) on gear box to ensure motor shaft and gear coaxiality (≤0.03mm); Drill fixing holes (Φ3mm) around the stop for stable motor installation.
- Curtain Fixing Slot Machining: Mill T-shaped slot (width 5mm, depth 3mm) on track bottom for curtain clips; Chamfer slot edges (C0.2mm) to avoid damaging curtain fabric.
- Limit Switch Hole Machining: Drill Φ6mm holes at track two ends for limit switches; Assurer la précision de la position du trou (± 0,1 mm) to trigger stop function when curtain reaches the end.
3.3 Inspection de la qualité de l'usinage
Conduct in-process checks to ensure quality:
- Inspection dimensionnelle: Use digital calipers (track length, gear outer diameter, tolérance ± 0,05 mm) and coordinate measuring machine (Cmm) (track teeth, gear profile, tolérance ± 0,02 mm).
- Surface Quality Check: Use surface roughness meter (Ra0.8-Ra3.2 for moving parts like gears/tracks, Ra3.2-Ra6.3 for fixed parts like control boxes); Vérifiez les rayures (no visible scratches >0.5mm) and burrs.
- Test d'ajustement: Assemble gear and track (test meshing smoothness, pas de brouillage); Install motor on gear box (verify shaft coaxiality, no vibration); Test curtain clip insertion into track slot (Facile à installer, no falling off).
4. Post-Processing and Assembly of Electric Curtain Prototypes
Post-processing enhances performance and durability, while precise assembly ensures functionality.
4.1 Traitement de surface
Different materials require targeted treatment to meet design goals:
| Matériel | Méthode de traitement de surface | But & Effet |
| Alliage en aluminium (Track/Gear Box) | Anodisation (noir/argent) + Sable | Anodization improves corrosion resistance (salt spray test ≥48 hours); sandblasting creates matte finish (reduces light reflection and fingerprint adhesion). |
| ABS/PC (Control Box/Gear Box) | Peinture (matte white/gray) + Silk Screen | Painting matches home decor; silk screen prints brand logos and interface labels (Par exemple, “Pouvoir”, “Limit Switch”). |
| POM/Copper Gears | Ebat à l'huile (food-grade lubricant) | Réduit la friction (prolonge la durée de vie 30%) and operating noise (≤50dB). |
| Steel Gear Shafts | Placage chromé | Améliore la résistance à l'usure (avoids rust in humid environments). |
4.2 Assemblage et tests fonctionnels
Scientific assembly and strict testing ensure the prototype meets requirements.
4.2.1 Processus d'assemblage
Follow this sequence to avoid errors:
- Vérification avant assemblage: Inspect all parts for defects (pas de rayures, dimensional deviation ≤0.05mm); Prepare auxiliary materials (huile de graissage, vis, fils, curtain fabric/PVC sheet).
- Component Installation:
- Drive Mechanism Assembly: Install gear on motor shaft (use keyway for fixation); Mount motor and gear into gear box (fixer avec des vis M3, torque 0.8-1N·m); Apply lubricating oil to gear teeth.
- Track Assembly: Connect gear box to track (ensure gear meshes with track inner teeth); Install limit switches at track ends (wire to control module); Fix track to wall brackets (spacing 500mm for stability).
- Control System Assembly: Install PCB module in control box (fasten with M2 screws); Connect motor, limit switches, and power interface to PCB; Close control box cover (snap-fit or screw fixation).
- Curtain Installation: Attach curtain clips to fabric/PVC sheet; Insert clips into track T-slot (even spacing 150mm).
- Final Check: Ensure no loose parts; Verify gear meshing (pas de lacunes); Check curtain alignment (no tilt).
4.2.2 Tests fonctionnels
Conduct comprehensive tests to validate performance:
- Tests fonctionnels:
- Opening/Closing Test: Run curtain 100 fois (forward/reverse, speed 5-10cm/s, no stuck);
- Limit Control Test: Verify curtain stops automatically at track ends (response time ≤0.5s);
- Test de chargement: Add 2kg weight to curtain (simulate heavy fabric), test normal operation (no motor overload);
- Control Test: Use remote/APP (le cas échéant) to control curtain (response time ≤1s, no delay).
- Tests de durabilité:
- Continuous Operation Test: Run curtain for 2 heures (intermittent, 5min on/1min off, no motor overheating);
- Vibration Test: Apply 10-500Hz vibration (acceleration 5m/s²) pour 1 heure, check for loose parts;
- Environmental Test: Place in 0-40°C environment for 24 heures, fonctionnalité de test (pas d'échec).
- Safety Testing:
- Insulation Test: Check control box for electric leakage (resistance ≥100MΩ);
- Overload Protection: Simulate motor jam, verify auto-stop (current ≤1.5A).
5. Application Scenarios of CNC Machined Electric Curtain Prototypes
CNC machined electric curtain prototypes serve multiple purposes in product development and market promotion:
| Scénario d'application | Specific Uses | Advantage of CNC Machining |
| Product Design Verification | Test track smoothness, gear meshing, and limit control; Optimize structure (Par exemple, adjust track teeth module for lower noise). | Haute précision (± 0,02 mm) ensures accurate simulation of mass production models; supports rapid iteration (modify 3D models, re-machine in 3-4 jours). |
| Market Research | Display at home decor exhibitions; Collect user feedback on appearance (couleur, track size) et les fonctionnalités (noise level, control method); Adjust mass production plans. | Prototype appearance/functionality matches final products; attracts user attention (high-quality surface treatment). |
| Personnalisation en petits lots | High-end home customization (curved tracks, couleurs personnalisées), hotel projects (uniform design); Produce ≤50 units without opening molds. | Flexible (adapt to custom designs like curved tracks quickly); rentable (pas de frais de moisissure, lower than injection molding for small batches). |
| Educational Training | Disassemble to demonstrate transmission mechanism (gear-track meshing) and CNC machining principles; Suitable for mechanical engineering/industrial design teaching. | Clear internal structure (easy to observe components); sûr (meets insulation standards, no electric shock risk). |
6. Key Precautions for CNC Machining Electric Curtain Prototypes
To ensure quality and efficiency, observe these precautions:
- Contrôle de précision: Strictly control track teeth accuracy (± 0,02 mm) and gear coaxiality (≤0.03mm) to avoid jamming; Reserve ±0.1mm tolerance for mounting holes to facilitate assembly.
- Material Adaptation: Alliage en aluminium: Use cutting fluid to avoid overheating deformation; Pom: Control cutting speed (8000-12000 RPM) Pour éviter la fonte; Abs: Dry before machining to avoid bubbles.
- Optimisation des coûts: CNC machining is ideal for ≤100 units; pour la production de masse (>1000 units), switch to injection molding (ABS/PC parts) et extrusion (aluminum alloy tracks) to reduce cost by 50-60%. Simplify track design (Par exemple, replace complex curves with straight sections) to shorten toolpaths.
- Safety Operation: Wear safety glasses/gloves during machining; Use fume extractors for painting/anodization; Ground equipment to prevent electric shock when testing control modules.
Point de vue de la technologie Yigu
À la technologie Yigu, nous croyons CNC machining is the core to developing reliable electric curtain prototypes. It enables precise control of critical transmission components—from track inner teeth (Précision de ±0,02 mm) to gear coaxiality (≤0.03mm)—and supports rapid iteration, which is vital for balancing functionality (smooth operation, faible bruit) et durabilité (chargé de chargement, résistance à la corrosion) in electric curtains. When producing these prototypes, we focus on two core aspects: material-function matching (aluminum alloy for load-bearing tracks, POM for low-noise gears) et l'optimisation du processus (spiral interpolation for tooth accuracy, multi-point fixtures for long tracks). By integrating strict quality control from design to testing, we help clients shorten development cycles by 25-30% and mitigate mass production risks. Regarder vers l'avenir, we will apply AI-driven parameter optimization to CNC machining, further improving efficiency while maintaining ±0.02mm precision for more refined electric curtain prototypes.