CNC machine tool industrial wiring harness

The CNC machine tool industrial wiring harness is a wiring harness designed specifically for CNC machine tools. It is mainly used to connect servo motors, sensors, controllers, and other components to transmit signals and power supply. CNC machine tools need to operate continuously for 24 hours and achieve micron-level precision. Therefore, the reliability of the wiring harness directly affects the processing accuracy and the number of downtimes. This wiring harness, produced by Kaweei's professional wiring harness customization factory, has been strictly verified from materials to production processes. It can stably connect the CNC system and various components to ensure the normal operation of the machine tool.

Advantages of core material characteristics: Deep adaptation to CNC machine tools

1. Cable body: oil-resistant, wear-resistant, and low-loss transmission triple protection

Adopt NON-UL 4C composite structure (bare copper alloy 150/0.08 + 750D Nylon + gray PVC 80P oil-resistant layer), outer diameter 7.0mm:

• The alloy bare copper conductor (150/0.08) is made of 150 strands of high-purity alloy bare copper with a diameter of 0.08mm. The conductivity is ≥98%IACS, and the DC resistance is ≤0.25Ω/m. It can ensure low-loss transmission of servo motor control signals and encoder feedback signals with signal delay ≤0.02ms. Its multi-strand twisted design allows the wire to have a bending life of ≥100,000 times (bending radius ≥7mm), which can resist the risk of wire breakage caused by 5-500Hz high-frequency vibration of CNC machine tools.
• The tensile strength of the tensile inner layer of 750D nylon material is ≥200N, which can withstand the continuous pulling force caused by the machine tool tool changing mechanism and the drag chain movement, protect the internal 4C core wire, and avoid the core wire breakage and equipment shutdown when the machine tool is frequently started and stopped and quickly fed.
• The grey PVC 80P oil-resistant insulation layer adopts an 80P high-density woven structure to strengthen mechanical protection. After 1000 hours of emulsion/synthetic cutting fluid immersion test, the volume resistivity is still ≥10¹²Ω・cm. The surface Shore A hardness is 85, and the wear resistance is 30% higher than that of ordinary PVC. It can effectively block oil erosion and has a service life of ≥5 years under normal working conditions.

2. Interface components: precise connection and security protection

• The right-end plastic shell adopts TE AMP Connectors 172159-1. Its 4-pin design precisely matches the 4C core wire (black 1, black 2, black 3, green), and the pin pitch is 4.14mm, which can ensure that key signals such as spindle control and feed axis drive are transmitted independently without interference. The high-strength engineering plastic made of PA66 nylon can withstand more than 5,000 plug-in and pull-out times, and the contact resistance change is ≤10mΩ, which is suitable for mainstream industrial control system interfaces.
• The left terminal uses an 18AWG blue nylon insulated pin terminal (E1008). The outer nylon insulation layer has passed the 1000V AC withstand voltage test, and the leakage current is ≤0.5mA. It can isolate the high-voltage circuit of the spindle drive and the low-voltage circuit of the control board. The 18AWG wire gauge can stably carry 5-8A current, effectively isolate strong and weak electricity, and avoid short circuits when the electrical cabinet is densely wired. The blue appearance also makes it easy for maintenance personnel to quickly identify key lines.

3. Heat shrink tubing system: 125℃ temperature resistance + 600V voltage resistance double protection

• The right end interface sleeve is black, 125℃ specification (∅14.0mm*50mm). After shrinking, it can reach an IP65 protection level, can resist cutting fluid splash and metal debris intrusion, and the insulation resistance drops by no more than 10% after 72 hours of oil resistance test.
• The left end interface sleeve is black 125° specification (∅8.0mm*25mm), which can accurately fix the terminal position. In the vibration test, the terminal displacement is ≤0.1mm, which ensures that the connection will not loosen under the high-frequency vibration of CNC.
• The baking casing process uses 120-130℃ segmented heating and positive pressure shaping to make the casing shrinkage rate ≥50%, with no bubbles or wrinkles on the surface, and the probability of protection failure is less than 0.1%.

Production process precision control: millimeter-level manufacturing standards

1. Wire cutting and stripping: Accurate reservation of CNC installation space

• Length design: A fully automatic wire cutting machine is used, and the wire cutting length error is controlled within ±0.5mm. Strictly implement the standard of 90mm for the left end and 33mm for the right end to ensure that the reserved length is accurately adapted to the welding and connector installation requirements of the machine tool control board. The flatness of the laser peeling cut is ≤0.05mm, and the yield rate is ≥99.5%.

2. Tinning of core wires and riveting of terminals: zero defects in electrical connection

• Lead-free tinning process: 0.3-0.6mm tin layer at the front end of the core wire, no oxidation after 48 hours of salt spray test, signal transmission error ≤0.01%;
• 9.08Kgf tensile force standard: The terminal and the core wire are riveted by using a high-precision terminal crimping machine with a pressure range of 2-5KN, ensuring that they can withstand a tensile force of ≥9.08Kgf.

3. Full process testing: machine tool working condition simulation verification

• Continuity test: Multi-channel tester detects on-resistance ≤50mΩ;
• Insulation test: Insulation resistance ≥100MΩ under 500V DC voltage;
• Vibration test: Simulate the vibration frequency of machine tools at 50-500Hz, and continuously test for 100 hours to ensure that there is no looseness or circuit breakage.
• XRF RoHS2.0 detection: Use an X-ray fluorescence spectrometer to ensure that the content of harmful substances such as lead and cadmium is lower than the EU standard (such as cadmium ≤0.01%).
• Shell pull-out force test: Apply 30N pulling force to TE AMP 172159-1 shell, and it will not fall off for 1 minute, which meets UL 486A-486B standards.

Application scenarios and technical highlights

1. Core application scenarios

• Applicable to all types of CNC machine tools, including CNC lathes, machining centers, CNC grinders, etc. It can be used to connect CNC systems with core components such as servo drives, encoders, solenoid valves, spindle motors, etc. to transmit control signals and power.

2. Analysis of technical highlights

• The design of alloy bare copper conductor and 4C independent core wire can reduce the delay of synchronous transmission of multi-axis linkage control signals to no more than 0.02ms, thereby ensuring the processing accuracy of machine tools and achieving zero delay in signal transmission.
• The combination of oil-resistant and wear-resistant wire, high-reliability connector, and anti-loosening sleeve, plus 750D nylon tensile layer and 9.08Kgf riveting force, can operate stably in the high-frequency vibration and strong electromagnetic interference environment of machine tools. After passing the 100-hour 50-500Hz vibration test, the terminal connection is not loose, achieving strong vibration and interference resistance.
• Color-coded core wires (black 1/black 2/black 3/green) with blue terminal visual identification can increase wiring efficiency by 30%, shorten troubleshooting time to 30 minutes each time, and achieve efficient installation and maintenance.

Kaweei wire harness customization factory provides a reliable guarantee for the stable operation of CNC machine tools with customized materials, precise craftsmanship, and excellent performance. Whether it is the pursuit of higher processing accuracy or the improvement of equipment reliability and maintenance efficiency, the wire harness made by Kaweei factory is a trustworthy choice; if you need more product information or customized solutions, please feel free to contact us.