Application of the Xindashida Motion Control System in the Milling Groove Process for Smart Card Chip Embedding in the 3C Industry
2025-07-28
Application of the Xindashida Motion Control System in the Milling Groove Process for Smart Card Chip Embedding in the 3C Industry
Project Background
With the rapid development of IoT, financial payment systems, and identity authentication technologies, smart cards—serving as the core carrier—demand ever-increasing precision and efficiency in their manufacturing processes. In the smart card production process, the slotting operation is a critical step that determines the accuracy of chip embedding. The slotting machine uses a rotating cutter head to drive the milling cutter at high speed, precisely cutting slots of the same size as the chip and conforming to industry standards on standard-sized cards.
Traditional manufacturing processes, constrained by the capabilities of their control systems, struggle to meet the demands of high-precision and flexible production. The Xinshidada motion control system, through iterative upgrades of host-computer technology and control cards, is driving the intelligent card slotting machine toward a leapfrog development toward intelligence and high precision.
Customer needs
Smart card grooving is a precision process that involves machining recesses into substrates such as PVC and ABS to embed components like chips and antennas. The core process includes:
High-speed cutting: Using milling cutters rotating at speeds ranging from 20,000 to 60,000 revolutions per minute, the cutting process is carried out along a pre-set trajectory under the control of an X/Y/Z-axis servo system.
Dynamic compensation: Real-time monitoring of the machining status via sensors to compensate for deviations caused by material deformation or equipment vibration.
Parameter adaptation: Automatically adjusts the spindle speed and feed rate based on material characteristics (e.g., for PVC, the feed rate is 500–1000 mm/min).
Precision requirements: The tolerances for groove depth and width must be controlled within ±0.05 mm, and the surface roughness Ra must be ≤1.6 μm, conforming to international standards such as ISO 7810.
However, traditional control systems have obvious bottlenecks:
The number of axes is limited (e.g., only 4 axes), making it difficult to support the machining of complex, irregular-shaped slots. The pulse frequency is low (≤4 MHz), which restricts the motor from operating at high speeds. The buffering capability is weak, leading to potential instruction delays when multiple axes are coordinated. The interpolation function is simplistic and unable to handle spatial curved trajectories.
Xinshida Solution
Scheme Composition
This application solution is equipped with an advanced motion control system and a servo system. The motion control system uses the ADT-8909 series motion control card, while the servo system features the Sinamics Ω6 series.
Scheme advantages
The new-generation control card, exemplified by the ADT-8909 series, empowers intelligent card slotting machines across the board through six major technological innovations.
• Multi-axis, multi-card expansion: Supports complex collaborative scenarios.
The ADT-8909 series offers multi-axis configurations with 4, 6, and 8 axes, far exceeding the limitations of traditional 4-axis systems. Its multi-axis synchronization capability is well-suited for complex machining requirements such as irregular grooves and curved surfaces, laying a solid hardware foundation for flexible smart card production. For example, an 8-axis multi-card system can simultaneously control the milling cutter feed rate, spindle speed, material translation, and auxiliary pressing mechanisms, enabling synchronous operation across multiple processes.
• High-frequency pulse output: Enhances motion control precision
The pulse output frequency reaches up to 5 MHz (compared to only 4 MHz in conventional systems), enabling motors to operate at higher speeds. In precise milling groove trajectory control, the high-frequency pulses significantly reduce lost steps, ensuring the continuity and accuracy of the machining path.
• Digital I/O Expansion: Enhancing Device Sensing Capabilities
The system features up to 42 digital inputs and 24 outputs (compared to just 8 inputs and 8 outputs per axis in conventional systems), enabling it to connect more sensors—such as those for pressure, temperature, and vibration monitoring—as well as actuators, thus facilitating end-to-end process monitoring and closed-loop control across the entire production line. For example, pressure sensors provide real-time feedback on the contact force between the milling cutter and the material, preventing overcutting or undercutting caused by uneven material hardness; temperature sensors, in turn, coordinate with the cooling system to prevent deformation due to high temperatures.
• Advanced cache control: Ensures smooth instruction execution.
It supports advanced features such as speed lookahead, cached I/O events (with a capacity of up to 1,000), cached output control, and NURBS curve interpolation. Speed lookahead predicts the acceleration and deceleration processes to optimize trajectory planning; the large-capacity cache ensures that multi-axis interpolation commands are executed without delay, thereby preventing machining jitter.
• Multidimensional Imputation Function: Expanding the Scope of Process Applications
In addition to basic linear and circular interpolation, new features such as spatial arc interpolation, helical interpolation, and synchronous follow-up have been added. For example, helical interpolation enables efficient machining of ring antenna slots in smart cards, while spatial interpolation supports the one-step forming of three-dimensional curved slot structures, significantly reducing the number of processing steps.
• A9 Dual-Core Platform: Enhancing Real-Time Computing Performance
Equipped with a high-performance dual-core A9 processor, its computing power is significantly enhanced compared to traditional platforms. It can process multi-axis trajectory calculations, adaptive parameter adjustments, and process data modeling in real time, ensuring precise response of control commands even at high speeds.
Associated products
ADT-8989 C1/H1 High-performance eight-axis pulse motion control card based on the PCI bus
Singlina Ω6-A Servo Drive
Project Results
Development Efficiency Optimization
We provide a standardized API replacement solution that significantly simplifies the customer’s software system upgrade process, directly reducing software replacement development effort by 40% and lowering both the time and labor costs associated with customer technology upgrades.
A leap in machining accuracy
Through real-time dynamic compensation and adaptive parameter adjustment technologies, the slot depth tolerance is stably maintained within ±0.03 mm, and the surface roughness Ra is ≤0.8 μm. The precision indicators exceed industry standards by more than 50%. Measured data from a certain company show that after the upgrade, the yield of chip embedding has increased from 95% to 99.2%, significantly reducing the rework rate and material waste costs.
Production efficiency breakthrough
Relying on a 5 MHz high-frequency pulse output and multi-axis collaborative control, the machining speed is increased by 30%. Coupled with NURBS continuous trajectory optimization technology, the processing cycle per card is shortened by 15%. Taking a production line with an annual capacity of 100 million sheets as an example, this efficiency improvement can directly save approximately 1.2 million yuan per year in equipment investment costs, while also reducing order delivery times by 20% and enhancing the company’s ability to respond quickly to customer market demands.
