1. Pre-CNC Machining: Design and Preparation for Electric Curtain Prototypes
Before initiating CNC machining for the electric curtain prototype, a systematic design and preparation stage is critical to meet functional, structural, and user experience requirements. This stage follows a linear sequence, with key details organized in the table below.
| Design Step | Key Requirements | Recommended Materials |
| Product Demand Analysis | Core functions: Smooth curtain opening/closing (speed 5-10cm/s), forward/reverse rotation, limit position control; Structural requirements: Track load-bearing capacity (≥2kg), drive mechanism torque (≥0.5N·m), curtain body compatibility (cloth/PVC soft curtain); Appearance: Hidden screws, matte track surface (reduces light reflection); Reserve space for motor, gear set, PCB control module, and power interface (DC 12V). | – |
| 3D Modeling & Structural Design | Use CAD software (SolidWorks, UG NX) to create 3D models with precision (tolerance ±0.05mm); 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 (thickness 1.5-2mm) to avoid deformation under load. | – |
| Material Selection | Choose materials based on component function, machinability, and durability, while matching mass production standards. | Track/Gear Box: Aluminum alloy 6061/6063 (lightweight, wear-resistant, thickness 2-3mm); Motor Mount/Control Box: ABS/PC alloy (low cost, insulation, thickness 1.5-2mm); Gears: Copper/steel (high torque, wear-resistant) or POM plastic (low friction, low noise); Curtain Fixing Clips: Nylon (lightweight, corrosion-resistant). |
| Material Pretreatment | Cut raw materials into blanks (leave 0.5-1mm machining allowance): Aluminum alloy via bandsaw, ABS/POM via laser cutting; Anneal aluminum alloy (300-350°C for 1-2 hours) to reduce internal stress; Dry ABS/POM (80-100°C for 2-3 hours) to remove moisture (prevents machining bubbles); Clean all blanks with alcohol to remove oil and dust. | – |
2. CNC Machining Preparation for Electric Curtain Prototypes
Adequate preparation before formal machining ensures efficiency and precision in CNC machining for electric curtain prototypes. This section covers tool selection, programming, and fixture design.
2.1 Material and Tool Selection
The choice of materials and tools directly affects machining quality and efficiency. The table below provides detailed recommendations:
| Category | Specific Options | Application Scenarios |
| Structural Materials | Aluminum alloy 6061 plate (2-3mm), ABS/PC plate (1.5-2mm), POM rod (diameter 8-12mm) | Aluminum alloy for tracks/gear boxes (load-bearing); ABS/PC for control boxes (insulation); POM for gears (low friction). |
| Transmission Materials | Copper rod (diameter 5-8mm), steel sheet (1-1.5mm) | Copper for high-torque gears; steel for gear shafts (wear-resistant). |
| Rough Machining Tools | Φ8-12mm flat-bottom cutter (aluminum alloy/ABS), Φ6-8mm flat-bottom cutter (POM) | Quick material removal for large components (tracks, control boxes). |
| Finishing Tools | Φ2-4mm ball-head cutter (track inner teeth), Φ1-2mm root-clearing cutter (gear grooves), Φ3-5mm drill bit (mounting holes) | Ensure precise details (track teeth, gear profiles) and smooth surfaces (Ra0.8-Ra3.2). |
| Special Tools | M3-M5 taps (threaded holes), gear milling cutter (module 0.5-1), thread milling cutter (large holes) | Process assembly threads and gear teeth (ensure meshing accuracy). |
2.2 Programming and Fixture Design
Scientific programming and stable fixtures prevent machining errors and ensure precision.
| Link | Key Operations | Purpose & Effect |
| CAM Programming | – Sub-zone machining: First process track outer contour, then inner teeth; Machine gear box cavity before assembling with gears to avoid interference.- Layered cutting: Set roughing depth 0.5mm (aluminum alloy/ABS) or 0.2mm (POM); finishing depth 0.1-0.2mm.- Spiral interpolation: Use for track inner teeth (ensures tooth profile accuracy ±0.02mm) and gear grooves. | Improve efficiency; ensure dimensional accuracy (±0.05mm) and smooth gear meshing. |
| Fixture Design | – 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 (even pressure, no damage); for small gears, use custom jigs for synchronous clamping.- Gear shafts: Use three-jaw chuck for turning (ensure coaxiality ≤0.03mm). | Maintain workpiece stability; avoid surface damage and dimensional deviation. |
3. Core CNC Machining Process for Electric Curtain Prototypes
The formal CNC machining process transforms design models into physical parts, with strict control over each step to ensure functionality and durability.
3.1 Main Component Machining
Different components require targeted machining steps, as detailed below:
| Component | Roughing Steps | Finishing Steps |
| Track (Aluminum Alloy) | 1. Mill outer contour (length 1000-1500mm, width 20-30mm, retain 0.5mm allowance);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) to avoid sharpness;3. Polish inner cavity walls (Ra1.6) for smooth gear movement. |
| Gear Box (ABS/PC) | 1. Mill outer shape (80×50×30mm, retain 0.5mm allowance);2. Mill motor mounting hole (Φ20mm) and gear cavity (matches gear size);3. Cut wire slots (width 3mm) for control module wiring. | 1. Smooth cavity walls (Ra3.2) to reduce gear friction;2. Tap M3 threaded holes (for motor fixation);3. Deburr wire slots to prevent cable damage. |
| Gear (POM/Copper) | 1. Turn rod into cylindrical blank (diameter matches gear outer diameter, retain 0.3mm allowance);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, retain 0.5mm allowance);2. Mill PCB cavity (depth 8-10mm) and power interface cutout (DC 12V size);3. Drill button holes (Φ5mm) for control switches. | 1. Smooth cavity walls (Ra3.2);2. Chamfer button holes (C0.3mm) for easy switch installation;3. Tap M3 threaded holes (for box cover assembly). |
3.2 Key Detail Machining
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 (±0.02mm) 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; Ensure hole position accuracy (±0.1mm) to trigger stop function when curtain reaches the end.
3.3 Machining Quality Inspection
Conduct in-process checks to ensure quality:
- Dimensional Inspection: Use digital calipers (track length, gear outer diameter, tolerance ±0.05mm) and coordinate measuring machine (CMM) (track teeth, gear profile, tolerance ±0.02mm).
- 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); Check for scratches (no visible scratches >0.5mm) and burrs.
- Fit Test: Assemble gear and track (test meshing smoothness, no jamming); Install motor on gear box (verify shaft coaxiality, no vibration); Test curtain clip insertion into track slot (easy to install, 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 Surface Treatment
Different materials require targeted treatment to meet design goals:
| Material | Surface Treatment Method | Purpose & Effect |
| Aluminum Alloy (Track/Gear Box) | Anodization (black/silver) + Sandblasting | 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) | Painting (matte white/gray) + Silk Screen | Painting matches home decor; silk screen prints brand logos and interface labels (e.g., “Power”, “Limit Switch”). |
| POM/Copper Gears | Oil Coating (food-grade lubricant) | Reduces friction (extends gear life by 30%) and operating noise (≤50dB). |
| Steel Gear Shafts | Chrome Plating | Enhances wear resistance (avoids rust in humid environments). |
4.2 Assembly and Functional Testing
Scientific assembly and strict testing ensure the prototype meets requirements.
4.2.1 Assembly Process
Follow this sequence to avoid errors:
- Pre-Assembly Check: Inspect all parts for defects (no scratches, dimensional deviation ≤0.05mm); Prepare auxiliary materials (lubricating oil, screws, wires, 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 (fasten with M3 screws, 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 (no gaps); Check curtain alignment (no tilt).
4.2.2 Functional Testing
Conduct comprehensive tests to validate performance:
- Functional Testing:
- Opening/Closing Test: Run curtain 100 times (forward/reverse, speed 5-10cm/s, no stuck);
- Limit Control Test: Verify curtain stops automatically at track ends (response time ≤0.5s);
- Load Test: Add 2kg weight to curtain (simulate heavy fabric), test normal operation (no motor overload);
- Control Test: Use remote/APP (if applicable) to control curtain (response time ≤1s, no delay).
- Durability Testing:
- Continuous Operation Test: Run curtain for 2 hours (intermittent, 5min on/1min off, no motor overheating);
- Vibration Test: Apply 10-500Hz vibration (acceleration 5m/s²) for 1 hour, check for loose parts;
- Environmental Test: Place in 0-40°C environment for 24 hours, test functionality (no failure).
- 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:
| Application Scenario | Specific Uses | Advantage of CNC Machining |
| Product Design Verification | Test track smoothness, gear meshing, and limit control; Optimize structure (e.g., adjust track teeth module for lower noise). | High precision (±0.02mm) ensures accurate simulation of mass production models; supports rapid iteration (modify 3D models, re-machine in 3-4 days). |
| Market Research | Display at home decor exhibitions; Collect user feedback on appearance (color, track size) and functionality (noise level, control method); Adjust mass production plans. | Prototype appearance/functionality matches final products; attracts user attention (high-quality surface treatment). |
| Small-Batch Customization | High-end home customization (curved tracks, custom colors), hotel projects (uniform design); Produce ≤50 units without opening molds. | Flexible (adapt to custom designs like curved tracks quickly); cost-effective (no mold fees, 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); safe (meets insulation standards, no electric shock risk). |
6. Key Precautions for CNC Machining Electric Curtain Prototypes
To ensure quality and efficiency, observe these precautions:
- Precision Control: Strictly control track teeth accuracy (±0.02mm) and gear coaxiality (≤0.03mm) to avoid jamming; Reserve ±0.1mm tolerance for mounting holes to facilitate assembly.
- Material Adaptation: Aluminum alloy: Use cutting fluid to avoid overheating deformation; POM: Control cutting speed (8000-12000 RPM) to prevent melting; ABS: Dry before machining to avoid bubbles.
- Cost Optimization: CNC machining is ideal for ≤100 units; for mass production (>1000 units), switch to injection molding (ABS/PC parts) and extrusion (aluminum alloy tracks) to reduce cost by 50-60%. Simplify track design (e.g., 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.
Yigu Technology’s Viewpoint
At Yigu Technology, we believe CNC machining is the core to developing reliable electric curtain prototypes. It enables precise control of critical transmission components—from track inner teeth (±0.02mm accuracy) to gear coaxiality (≤0.03mm)—and supports rapid iteration, which is vital for balancing functionality (smooth operation, low noise) and durability (load-bearing, corrosion resistance) 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) and process optimization (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. Looking ahead, we will apply AI-driven parameter optimization to CNC machining, further improving efficiency while maintaining ±0.02mm precision for more refined electric curtain prototypes.