1、 Market situation of RF harness
Today's cars have become the communication center of driving. In order to increase the safety and entertainment of driving, an ordinary car includes high-end cars such as am, FM, satellite radio, GPS receiver, SIM card, reversing image, cellular radio frequency, Adams, etc. multi screen, Bluetooth, WiFi, millimeter wave radar, lidar, etc. in addition, it will be used for vehicles and vehicles, vehicles and infrastructure The interconnection communication between vehicles and pedestrians is v2x, which needs to realize data transmission and signal transmission through RF harness in the vehicle. RF harness plays the role of connecting functional components and host. Now RF harness widely used in on-board network mainly includes two kinds of harnesses: fachkreis automation and high speed data, abbreviated as fakra and HSD, This product has fully considered the redundancy and evolution of signal system from the beginning of research and development, so they are of great significance to the whole on-board network system related to steam system safety.
Fakra conductor is a coaxial cable, which is divided into five layers from inside to outside: conductor (single strand solid wire or multi strand stranded wire), plastic insulator, aluminum foil shielding layer, braided mesh shielding layer and wire sheath. The central conductor and shielding layer form a current circuit. Because the central conductor and the other four layers are coaxial, they are named. At present, there are two kinds of wire diameters commonly used in the automotive market: 0.14mm ² And 0.35mm ²。 It has the advantages of wide transmission frequency, less external electrical interference, strong confidentiality and fidelity, etc. HSD is a 4-core shielded wire.
"Fakra" is the abbreviation developed by Germany for "fachkreis automobile", which can be translated into "automobile expert group". The fakra connector specification was prepared by a sub committee within the German automobile manufacturing Committee. General fakra needs to meet American uscar and German fakra automobile standards. Fakra has high-performance, cost-effective RF characteristics. Fakra connector originated from Rosenberg. After more than 20 years of development, fakra has become a standard RF connector in the automotive industry and is widely used in the industry. With the rapid development of automobile technology in recent years, more and more intelligent functions that help to improve driving and riding comfort have been applied to cars, and experienced the process from high-end cars to standard daily household cars. From the current market point of view, the high shielding and low loss of fakra and HSD can raise the safety and reliability level of on-board multimedia entertainment system and automotive electronic system to a new level, so it is gradually welcomed by the market.
For joint venture brands and self owned brands, fakra and HSD are mostly used in joint venture brands, such as Changan Ford, Chery Jaguar Land Rover, Shanghai Volkswagen, FAW Volkswagen and SAIC GM. For traditional vehicles and new energy vehicles, compared with traditional vehicles, new energy vehicles pay more attention to driving feeling, so RF harness is used more, especially in the current wave of car making in China, such as Weilai, ideal, Xiaopeng, etc.
According to the statistics of the RF harness data of a harness company, before 2016, there were generally about 3 RF harnesses on ordinary cars, while there were about 10 on medium and high-end models. However, after 2018, there were 8 RF harnesses on ordinary cars, while there were about 15 on medium and high-end models. Since then, the annual purchase amount of RF harness calculated by the company's procurement department in recent years shows that this amount has increased steadily from 2010 to 2016, but its growth has accelerated and increased rapidly by 2017 and 2018. The latest statistics show that the purchase amount of RF harness in 2019 is about. For the fast-growing RF harness market, a RF harness manufacturing equipment that can reach the advanced level of foreign countries is very timely and important.
2、 Brief introduction of fakra harness production process
Fakra harness production process mainly includes three parts: coaxial cable preparation, connector assembly and product inspection.
1. Prepare coaxial cable
According to the size requirements of different product processes, the sheath, shielding layer, aluminum foil and insulating layer of coaxial cable shall be cut and stripped according to IPC 620 grade 3 standard.
1) The incision shall be neat, smooth and free of burrs.
2) The insulator shall be free from burns and damage.
3) The cut of the shielding layer is flush, and there is no long shielding wire.
4) The shielding layer shall be neat, smooth and free from scratch.
2. Assembly connector
The assembly process includes crimping sleeve, crimping central terminal, installing and crimping outer conductor and assembling plastic shell.
1) Crimping sleeve: in addition to ensuring the height and width of crimping, the maximum gap between the edge of sleeve and the edge of sheath after crimping shall not exceed 1mm.
2) Crimping center terminal: B-type section shall be carried out according to din60352-2 or according to the customer's enterprise standard. After the crimping is completed, the core wire cannot be paid. The deviation angle of the center line of the crimping part, the center line of the cable and the center conductor must meet the quality requirements, otherwise there will be the risk of poor installation of the outer conductor.
3) Installation and crimping of outer conductor: first, ensure the quality of the central conductor penetrating into the outer conductor and meet the requirements of interface size. It is better to be able to detect the correct size before crimping the outer conductor.
3. Product inspection
The mechanical and electrical properties of crimped products need to be tested. For the mechanical test, first check whether the position and size of the central conductor are qualified; The position of the central conductor relative to the outer conductor is convenient for the use of the matching end, that is, the test of coaxiality; Whether the product is damaged in appearance during processing; For the test of electrical performance, we need to conduct a comprehensive test on the product terminals to ensure that the terminals remain in good quality before leaving the factory.
1) Destructive drawing force detection
2) Low voltage on-off detection and high voltage detection
3) Coaxiality detection between central conductor and outer conductor
3、 Junquan fakra harness automation equipment helps the intelligent vehicle
The high efficiency and reliability of massive data transmission of intelligent vehicles are very important. Fakra has high-performance, cost-effective RF characteristics. It is a widely used component for intelligent vehicle data connection at present. It is mainly used in navigation system, remote control, on-board telephone, on-board TV, audio equipment, antenna and so on. The fakra harness intelligent full-automatic and semi-automatic products developed and manufactured by the company have been widely used in the intelligent assembly of fakra harness of intelligent vehicles.
In order to adapt to the assembly combination of fakra harness products, from the cutting and stripping of coaxial cables, the crimping of connectors and the detection of products, Junquan automation "Junquan" has designed and developed a series of functional modules focusing on quality prevention to meet the needs of customers for processing fakra harness. Taking Rosenberg's fakra 3 straight product as an example, how to realize intelligent assembly between the outer conductor and inner conductor of coaxial cable and the outer conductor assembly, central terminal and support sleeve of connector is based on the understanding of key processes.
First, prepare the coaxial cable. The setting out module pf-6s (as shown in the figure below) can carry 350kg coaxial spool, built-in braking function, line buffer above 10m, wireless detection, knot alarm and other functions. The wire breaking module jq-sc perfectly integrates straightening, wire sending, measurement and wire breaking to ensure the length accuracy and the section fully meets the appearance standard requirements of IPC 620. When the long line needs to be looped, the single reel bs-40 and double reel dc-60 (below) standard takeup can effectively improve the production efficiency. In particular, the efficiency of the double reel takeup is more than 50% higher than that of the single reel.
The cutting and stripping quality of the coaxial line directly affects the quality of the final product. Multiple groups of blades must be designed according to the customer's cable, including v-knife, r-knife, rotary knife and their combinations. All cutting and stripping modules are mature and reliable standard modules and controlled by servo motor to accurately control the processing accuracy of products. At the same time, rapid tool change and waste collection must be considered. When cutting and stripping the cable, it is very important not to scratch the inner conductor and shielding wire to ensure the accuracy of signal transmission. When cutting and stripping the sheath and insulator, it should be well protected. It is not a simple problem of cutting and stripping, but how to ensure no scratch. In addition, the prevention of residual shielding wire should be considered in place during the processing of all cutting and stripping modules.
Before each crimping of crimping equipment, the crimping module first detects the materials to ensure qualified incoming materials. During crimping, it is equipped with pressure sensing device for real-time detection. According to the requirements of customers, visual inspection can be applied to detect the assembly size, quality and appearance after crimping. The molds customized according to the connectors of different manufacturers can realize the crimping of different terminals, and the type change is also very convenient. There are corresponding modules for products wearing waterproof plugs, which can meet the needs of wearing different waterproof plugs through large supporting rapid type change.
The fakra harness intelligent assembly line designed and developed by "Junquan" integrates the standard equipment and mold functions, with a yield of more than 99% and a production beat of 10 seconds, which effectively ensures the production quality and efficiency. More importantly, it improves the safety and reliability of fakra harness products. This intelligent assembly line applies a large number of sensors for quality prevention and control of detection and monitoring, and adopts information software system control (as shown in the figure below), which realizes all functions of automatic setting out, disconnection, cable cutting and stripping, crimping terminal, automatic installation of plastic shell and quality detection. The product processing data is displayed in real time, and the quality data can be stored and traced.
System structure diagram
The information software system realizes the functions of MES automatic order distribution, automatic product identification, automatic adjustment of machine parameters, real-time monitoring and recording of product status in the production process, massive data storage, product traceability, networking of Internet of things, etc. the system architecture mainly includes information integration center, main control PLC control center, pressure relay monitoring system, material mold confirmation module, continuity detection, depth detection module, electrical measurement system, vision system, etc. The main control PLC is the control center of the whole fakra assembly line, which controls the large cycle of vehicle station, collects alarm information, coordinates the flow operation of each work station, and records the working status of all work stations in the main control PLC. The information integration center is the data center of the whole fakra assembly line, including production task management, formula management, label generation module, material mold confirmation module, cable processing status monitoring, station status monitoring, data collection, data statistics, etc. the system will communicate with the main PLC in real time and with each detection and control unit system in real time to synchronously record the processing status of each cable and the status of the station.
The guarantee of the processing quality of the wire harness comes from the strict control in the processing process, so that the prevention and inspection are required. Each production station has automatic quality inspection tools, such as automatic detection and compensation of peeling length, automatic correction of terminal crimping position, crimping quality judgment and sorting of advantages and disadvantages. The final conformity of the product is reflected by electrical test, depth test and concentricity test.
4、 Introduction to monarchy automation
Junquan automation, founded in 1985, consists of Zhejiang Junquan automation equipment Co., Ltd., Jiaxing Junquan automation equipment Co., Ltd. and Shanghai Junquan automation equipment Co., Ltd. It is a national high-tech enterprise, a software enterprise in Zhejiang Province and a production base of provincial high-tech research and development center. The company has passed ISO9001 international quality system certification and fully implemented 6S modern enterprise management.
"Junquan" focuses on the production of automotive wire harness processing automation equipment, electrical connector automation equipment and the research and development of industrial automation technology and peripheral products, involving the automotive industry, electronics and appliances, aerospace, wireless communication and other fields. The products have passed CE, VDE, UL and other international certification and are sold to more than 50 countries and regions around the world. The "Junquan brand" has registered its trademark in Germany, Italy, Turkey, India and other countries, A number of overseas technical service centers have been established.
As an "expert of wire harness automatic processing equipment", "Junquan" series products have been recognized as national key new products, provincial high-tech products and provincial software products. They have been listed in the national torch plan project, won the National Innovation Fund Award twice, provincial and municipal science and technology progress awards many times, and have more than 50 national patents.
Jiaxing Junquan automation, founded in 2010, covers an area of 150000m2 with a registered capital of 50 million yuan. It is located in Jiaxing National Economic Development Zone in the northeast of Zhejiang Province and the hinterland of Hangjiahu Plain in the Yangtze River Delta. It has obvious geographical advantages and convenient water, land and air transportation. The company has a strong technical R & D team, advanced production equipment and perfect management system, integrating modernization, scientific and Technological Development and diversified development.
"Junquan" brand wire harness automation equipment sells well in more than 50 countries and regions around the world. In China, at least 3000 wire harness enterprises use "Junquan" brand wire harness automation equipment, more than 30000 "Junquan" brand wire harness automation equipment are widely used in the fields of automobiles, household appliances, electrical equipment and communication, and more than 80% of users continue to purchase "Junquan" brand wire harness automation equipment.
Over the years, the company has taken the development of "integrated, intelligent and environment-friendly" new products as the core, enjoyed high popularity in the field of peers at home and abroad, and achieved a world leading position in industrial automation technology. Monarchy automation is moving towards the goal of "world technology, global sharing".
