With the advancement of the global smart network-linked vehicles and the “Made in China 2025†plan, the important position of the sensor technology and sensor industry has become increasingly prominent. As an important part of the perception layer of the Internet of Things, sensors have been widely used in the field of automobile safety configuration, driving assistance, etc., and the industry changes brought about by this are also emerging. On September 12th, the China International Sensor Technology and Application Exhibition was held in conjunction with the Shanghai International Convention and Exhibition Center. For this reason, the reporter interviewed many guests on many issues in the field of domestic automotive sensors.
As we all know, 90% of the automotive industry's innovation comes from automotive electronics innovation. Automotive sensors are front-end systems for information acquisition and analysis. There are generally two types: one is vehicle body sensing, including pressure, flow, acceleration sensors, and gyroscopes, and the other is environment sensing, including lidar, millimeter-wave radar, camera, and infrared Night vision and other intelligent sensing devices. The automotive safety technology has evolved from passive safety technology to active safety technology (smart driving assistance). The sensor system also extends from body electronic sensing to intelligent sensing, and the intelligentization of automobiles brings a huge market increase in smart sensing. At this exhibition, Sensata, Advantech, UST, Minxin Microelectronics and many other well-known domestic and international sensors and Internet of Things companies exhibited. The reporter interviewed Sensata and Advantech on the application and development of automotive sensors.
Reporter: As the global sensor, electrical protector, controller design and manufacturing companies, what are the highlights of this exhibition?
Sensata Greater China & India Market Director of Sensor Products Jia Yongping
Jia Yongping: We mainly do two parts of the product, one is the sensor, the second is the controller. And recently it acquired a company from Schneider Germany, adding a lot of products. Pressure, high temperature, speed, position. We focus on applications that are more difficult to implement. For example, our temperature sensors have no room temperature and only have 300 to 1200 degrees high temperature sensors, which are very technically demanding, difficult to do, and critical. Because the sensor market is very large, only in the area of ​​automotive sensors, 2020 is expected to reach a market size of US$25 billion, and the Chinese market will reach a market size of US$5.5 billion. The entire sensor field should reach more than 100 billion market dollars. Therefore, it is impossible for any one manufacturer to monopolize. Therefore, we are concerned with how to make differentiated products and use our own technological accumulation and technological innovation to do something that others cannot easily enter.
And all of our sensors are produced in China, such as the production bases in Changzhou and Chengdu, Jiangsu. Because we have many large customers in China, we need to provide the nearest products and the best services. Tire pressure sensors on the market may only have a loading rate of around 20%. We expect that 90% will be achieved after the introduction of urban regulations in 2020. Our tire pressure sensors have a market share of more than 50% in the world, and tire pressure sensors have been installed as standard in Europe and North America at 100%. We are designing and manufacturing ourselves, because the most important thing in tire pressure monitoring is the sensor, which is a big advantage for us.
Reporter: It is very important for many consumers to look at the air quality in the car. What solutions do we have?
Advantech’s Embedded Computing Core Group Business Director Hu Zhisheng
Hu Zhisheng: The theme of our press conference is two parts. The left part is the front-end architecture products and services of the Internet of Things, and there is the sensor part. We have an M2.com front-end sensor interface standard, because sensor and processing are not the same, there are various data such as temperature, sensing, gas, carbon dioxide, sensing humidity and so on its interface is not the same, the industry does not A unified standard leads to their respective agreements.
Advantech is based on the global coverage of industrial control. Therefore, we want to combine some leading companies that are more transparent in the front end. For example, Bosch, ST, TI, Freescale, and other leading companies, we lead in the establishment of a front-end The industry standard for sensor interfaces is currently defined as M2.com.
At the same time, we have brought a carbon dioxide sensor that is a carbon dioxide collector that includes temperature and humidity. We also have a sensor for the humidity of the air. In the car in the exhibition basement, including the site and our headquarters, there is a sensor that can be monitored at any time, whether it is carbon dioxide or air temperature, humidity, or a flow meter. The sensor plugs directly into the unified one. The drawbacks of the past are not consistent with ours. You have to use Bosch and use the Internet of Things. There is no way to use it. Therefore, we are determined to push the standards of M2.com in some industrial applications. Now we are advancing to the application of the Internet of Things and we are also collecting the data of individual individuals (including the human body) at the front end and sending them to the back. In addition to the application of this product in the smart home, it can actually be applied to the car's cabin.
Reporter: The sensors exhibited by UST this time are miniature. What technological innovation do we have?
Song Menghua: UST is a supplier of chips to the German automotive industry. Products from chips to sensors are used to convert physical and chemical quantities into electrical signals. The sensors are mainly temperature sensors and gas sensors, where the temperature sensor detection range is from minus 200 degrees to 1050 degrees. Temperature is the most frequently detected physical quantity in the industrial or daily fields. It is worth mentioning here that our company has established a long-term strategic partnership with Shanxi Runyi Auto Parts Technology Co., Ltd. and uses UST chips to produce high-temperature sensors in Yuncheng for the automotive industry. The significance is that this sensor breaks the monopoly of American products. So far, within China, there is only this ethnic enterprise.
What I just mentioned is that we have successfully entered the automotive industry in batches. We are working with the next step of cooperation with Runxi Shanxi and are also air quality sensors used in cars. It is used to detect the air quality outside the vehicle when the outside air When the quality deteriorates and it is harmful to the human body, the external circulation is actively closed. This feature is available in almost 80% of cars in Europe.
Reporter: What applications do you have for your products in the automotive industry?
Suzhou Minxin Microelectronics President Li Gang
Gang Li: One is that we do this kind of car after loading, intake air pipe, and this fuel steam, 5KP, as well as refrigerant sensors, automotive refrigerants, but also organic oil. There are many applications that can be derived from the automotive industry. Like our packaging, we can do DPS, but the packaging is not the same, that is, you can do car suspension. Now on the car, we can't do anything other than the high-range. Basically we have other core technologies, including your packaging and testing. Your chips are your own. I can customize this application for him according to the customer's needs.
The
Injection Molding
What is Precision CNC Milling
In general, computer numerical control milling machine (CNC) machining is a deductive manufacturing technique that programs 3-axis linkage, complex to 5-axis linkage, drives milling cutters to remove layers from solid blocks called blanks to produce finished parts. CNC milling is one of the main types of CNC Machining, which uses cutting tools that rotate at a speed of several thousand to tens of thousands of revolutions per minute (RPM) to precisely remove materials to obtain parts with complex surfaces. In addition to milling, CNC machining is also equipped with drills, boring tools, thread cutters and other tools to complete different part features at once. CNC machining produces parts based on a computer-aided design (CAD) model that is sent to a CNC machine through computer-aided manufacturing (CAM) software.
CNC Machining centers developed from CNC milling machines. The biggest difference compare to CNC milling machines is that the machining center has the ability to automatically exchange machining tools, by installing tools for different purposes on the tool magazine, the machining tools on the spindle can be changed through the automatic tool changing device in a single clamping device to achieve a variety of machining functions.
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CNC Milling Finish
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Process
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Roughness Ra(um)
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Cylindrical milling cutter milling (rough)
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12.5~3.2
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Cylindrical milling cutter (fine)
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3.2~0.8
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Cylindrical milling cutter (precision)
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0.8~0.4
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Cylindrical milling cutter (rough)
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12.5~3.2
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Cylindrical milling cutter milling (fine)
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3.2~0.8
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Cylindrical milling cutter milling (precision)
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0.8~0.4
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Cutter milling (fine)
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12.5~3.2
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End milling cutter (rough)
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3.2~0.4
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End milling cutter (precision)
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0.8~0.2
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High speed milling (rough)
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1.6~0.8
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High speed milling (fine)
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0.4~0.2
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CNC milling accuracy
CNC milling centers and high-Precision Machining centers. Ordinary machining center, resolution of 1μm, maximum feed speed of 15 ~ 25m / min, positioning accuracy of about 0μm. High-precision machining center, resolution of 0.1μm, maximum feed speed of 15 ~ 100m / min, positioning accuracy of about 2μm. Between 2 and 10 μm, with a ± 5 μm more, can be called precision grade. FCE equipped with different grade and different size CNC milling center. Take in to account into both economic and quality in parallel.
CNC Finishing surface treatment
Post-processing is the final step in the CNC machining process. In a quick guide, we offer a lot of surface treatments to complete your final parts and get them to meet strict specific requirements. It should be noted that in CNC machining, post-processing is in optional, as the quality of the machined parts is already very high.
Anodized
The anodizing process allows the part to obtain excellent corrosion resistance, increasing the hardness and wear resistance of the surface. Anodizing is also the most common pre-painting treatment, which can help the painted surface to obtain good adhesion. We typically apply two types of anodizing in our production: Type II, corrosion resistant; Type III is thicker, adding a layer of wear resistance. Both anodizing processes can achieve a variety of color effects.
Polishing
Grinding polish, it offers the fastest turnaround parts and does not require post-processing. The surface finish of the grinding part is equivalent to 125 um in Ra, and the requirements can be increased to 63, 32 or 16 um Ra. Minor tool marks may still be visible on the last part.
Powder coatings
Powder Coating is thermoplastic powder spraying directly on the processed part. The sprayed parts are then baked in an oven to form a durable, abrasion- and corrosion-resistant plastic coating. In the powder coating process, its color, brightness, surface roughness can be customized.
Shot blasting
Shot peening is the high-speed spraying of beads of different hardnesses and sizes onto the surface of the part. To get different textures and brightness of the surface. Since the surface has been hit by similar forging beads, the hardness and wear resistance of the surface have also been enhanced.
Design of CNC machining
CNC machining is a universal machining process, especially parts that can be cut and machined can be achieved through CNC, from simple shape shapes to complex curved structures. However, as with every manufacturing technique, CNC machining has some design limitations. We break them down as follows to ensure that your products are optimally designed to better fit the CNC machining process.
General Tolerance
When designing parts, the size of each part is different according to the application environment, working conditions, etc., and the requirements for the machining accuracy of the workpiece are also different. Although CNC machining can achieve very high machining accuracy, we should also be aware that demanding machining accuracy and accuracy (strict product tolerances) usually mean Longer production times and higher costs. If a specific tolerance is not specified in the product design, we recommend choosing at the following levels.
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Permissible deviations in mm for ranges in nominal lengths
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Tolerance Class Designation(Description)
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fine
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medium
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coarse
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very coarse
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0.5 up to 3
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±0.05
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±0.1
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±0.2
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--
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over 3 up to 6
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±0.05
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±0.1
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±0.3
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±0.5
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over 6 up to 30
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±0.1
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±0.2
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±0.5
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±1.0
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over30up to 120
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±0.15
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±0.3
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±0.8
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±1.5
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over120upto400
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±0.2
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±0.5
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±1.2
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±2.5
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over 400up to 1000
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±0.3
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±0.8
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±2.0
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±4.0
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over 1000up to 2000
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±0.5
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±1.2
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±3.0
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±6.0
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over 2000 up to 4000
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--
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±2.0
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±4.0
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±8.0
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The highest precision of our equipment is 0.001, and the recommended most precise machining requirements do not exceed +/-0.005mm
Interior angle
All internal vertical edges of our products need to have rounded corners instead of right angles. This is because the tools used in CNC milling are cylindrical, which means they cannot produce inner right-angled edges. The fillet required by this process is called the inner corner fillet. When designing parts, the larger the inner corner fillet, the more efficient the production process. Because of the larger fillets, larger diameter milling cutters can be used to increase milling speed, and fewer swaps can be made to improve accuracy.
Undercut
Undercut cannot be machined with standard milling cutters, so the use of retract slots for parts should be avoided when designing CNC machined parts. In particular, for non-standard inner contour shapes, customized machining tools are required, which will greatly increase processing time and costs. Secondly, if undercut can not be avoided, due to the limited length of cnc tools, the undercut can not be too deep. If they are too deep or the location is difficult to reach, they will not be able to be produced because the CNC tool cannot reach the machining location.
Chamber wall thickness
CNC machining requires your part design to meet minimum wall thickness requirements. In general, it is recommended to choose the thickest possible and avoid very thin or characteristic walls. This is because CNC tools processing thin-walled parts will cause vibration deformation, which may cause interruptions or damage, and the size is out of specification. The standard minimum wall thickness for CNC machined metals is 0.030" (0.76 mm) and for plastics is 0.060" (1.5 mm).
Thread
When designing parts, it is useful to choose the largest possible thread size because smaller taps have a higher risk of breaking during production. If possible, avoid using deep hole threads as they lead to higher production costs, especially when custom tools are required.
Metal
In principle, materials with high hardness are easier to process because better processing accuracy can be obtained, but they are limited by the hardness of processing tools, so the hardness of the generally recommended parts is 8 ~ 60HRC, and for metal materials, the hardness is greater than stainless steel Followed by cast iron, followed by copper, and finally aluminum, while the processing of ceramics, plastics, etc. belongs to the processing of non-metallic materials. Fast production time.
Polymer
Although CNC can process thermoplastics, the material properties of polymers still have many difficulties for CNC processing. First, due to poor thermal conductivity, many thermoplastics melt or bend when in contact with CNC milling machines or drill bits. Secondly, the processing of plastics, because the hardness is low, the size accuracy caused by the knife during product clamping and processing is not high. For those parts that do not have special requirements for the strength and hardness of the metal, thermoplastics can provide a cheaper alternative.
Cost optimization of machined products
Simplify product design
Simplifying product design while taking into account functionality usually saves production time and reduces production costs. Because the manufacture of complex structures and surfaces often requires complex longer passes, more layering to obtain the same fine contour quality. This means higher production costs.
Reduce cutter changes
Using the same milling machine machining features, larger and same internal fillets, can reduce the number of tools used to reduce machining time. For example, if a workpiece needs a 10mm end face milling cutter to process some features, it also needs a spherical milling cutter to process a curved surface, and a 2mm milling cutter to process a fine groove, which will require repeated tool changes and reduce the machining efficiency
Proper material selection
The choice of raw material for machining can have a significant impact on production time and costs for CNC machining. If possible, choose a material with good processability, such as brass or aluminum. For those applications that do not require metal hardness and strength, CNC machining of engineering plastics like PMMA and ABS also helps to reduce costs because the material blank is cheaper, and the processing efficiency is higher.
Tolerance and wall thickness
Higher tolerances and thinner wall thicknesses also increase THE CORRESPONDING CNC machining costs, as it takes time to achieve higher precision cutting. If your product or component can accept a larger size range, choose a lower tolerance to reduce production time and costs. The same is true for wall thickness: a larger wall thickness margin should be chosen.
Choice of surface treatment
Surface treatment is often the final stage of the CNC machining process, which can also affect the cost of your entire project. Choosing less surface treatment for your part or product can lead to better time and cost efficiency. FCE can recommend to you how to optimize the surface treatment to balance the conflict between cost and quality according to your final needs.
FCE Machining services
FCE facilities are equipped with the most advanced and highest precision 3, 4 and 5-axis CNC machines, which allows us to complete your order in record time
1. 15+ year work experience engineers
2. Fastest 5 days delivery
3. Prototypes can be machined as quickly as 1 day.
4. More than 200 metals and plastics material available in stock
5. Tolerances as low as +-0.005mm
6. ISO 9001: 2015 certified factory
7. 40+ CNC machines
8. 50,000+ machined parts per month
We cooperated with many world top 500 companies and awarded good responds alway
Injection Molding,Plastic Injection,Plastic Molding,Custom Injection Molding
Suzhou FCE precision electronics Co., LTD , https://www.fukeyifcesz.com