2D Frame Bending and Butt Welding All-in-One Machine: High-Efficiency Intelligent Manufacturing Solution for Pan Racks

Ⅰ. Equipment Overview

Equipment Name: 2D Frame Bending and Butt Welding All-in-One Machine

Industry Positioning: Specifically designed for iron frame products such as pan racks and kitchen hangers, integrating automated wire bending and high-frequency welding processes to achieve a full-process closed-loop production of 3-8mm iron wires from feeding to finished frames. Aiming at the strict requirements of kitchen racks for load-bearing strength and structural stability, the equipment solves pain points such as frame deformation and virtual solder joints in traditional manual bending and welding with ±0.5mm-level precision and a production speed of 10-15 pieces/min, becoming the core equipment for large-scale production of kitchenware.
Technical Core: Equipped with a 32-bit PLC control system and Yaqi servo system, supporting the storage of 4,000 groups of production data. It realizes flexible production of components such as pan rack frames, hooks, and support rings through 300 action combinations, and achieves high-strength solder joint forming with a 63KW welding transformer.

Ⅱ. Analysis of Core Technical Parameters and Performance

(1) Electrical and Power System

(2) Mechanical Forming System

• Wire Feeding and Straightening Components:
  • Number of wire feeding wheels: 3 groups, made of Cr1MOV wear-resistant material, supporting universal feeding of round/flat/square wires (3-8mm), with smooth and non-slip wire feeding;
  • Straightening mechanism: Multiple straightening wheels cooperate with servo drive to ensure that the straightness error of iron wires is <0.3mm, laying the foundation for subsequent bending precision.
• Bending and Welding Mechanisms:
  • Bending molds: 12 groups of adjustable molds (material Cr12, hardness 58-62HRC), supporting up/down movement and 360° rotation of inner/outer molds, realizing the forming of complex shapes such as arc borders and right-angle hooks of pan racks;
  • Mechanical hand clamps: 2 sets of pneumatic clamps, positioning accuracy ±0.2mm, cooperating with the welding transformer to complete frame butt welding, with smooth and burr-free solder joints.
• Cutting and Auxiliary Systems:
  • Cutting force of the cutter motor: Suitable for cutting 3-8mm iron wires, with a cut perpendicularity ≤1°, meeting the surface finish requirements of kitchenware;
  • Pneumatic system: 9 cylinders + 5 solenoid valves, 0.6MPa pressure drives actions such as feeding, discharging, and welding, with a response time <50ms.

(3) Precision and Efficiency Indicators

• Production efficiency: 10-15 pieces/min (taking a 200*200mm square frame as an example), which is more than 6 times higher than traditional manual efficiency, supporting batch production of main frames and shelf supports of pan racks;
• Forming precision:
  • Bending precision ±0.5mm, ensuring that the diagonal error of the frame is <1mm;
  • Wire feeding precision ±0.5mm, ensuring the interface fit during multi-component splicing;
  • Solder joint position precision ±0.3mm, meeting the strength consistency requirements of load-bearing structures.

Ⅲ. Core Advantages of the Equipment

1. Flexible production capability:

• Supports frame forming with a circumference range of 30-700mm. Through the storage of 4,000 groups of data and 300 action combinations, it can quickly switch products such as single-layer/multi-layer structures of pan racks and hooks of different sizes, with a model change time <5 minutes;
• Compatible with materials such as Q235 carbon steel and galvanized iron, meeting the food-grade contact standards and anti-rust requirements of the kitchenware industry.

2. Intelligent control and visual operation:

• Chinese/English bilingual system, touch screen + button dual-operation mode, supporting production data upload and download. Novices can take up their posts after 2 hours of training;
• Real-time monitoring of parameters such as bending angle and wire feeding length, automatic alarm and shutdown in case of abnormalities, reducing the rejection rate to below 1%.

3. Energy saving and durability:

• Total power 7.8kW, 35% more energy-saving than traditional equipment. With a water cooling system, the temperature of core components is ≤65℃, and the continuous operation life of the equipment exceeds 100,000 hours;
• The mold is precision-machined with SKD11, with a service life of more than 150,000 times, reducing maintenance costs.

Ⅳ. Application Scenarios: Full Process Coverage of Pan Racks

• Main frame forming:
  • Circular/square frame making and welding with a diameter of 300-600mm, as the main support of the pan rack, with a load-bearing capacity of more than 15kg, meeting the needs of multi-layer stacking;
  • 180° bending angle combined with a 360° rotating die head realizes the flanging process of the frame edge, preventing hand scratches and enhancing structural strength.
• Functional component processing:
  • Hook components: Small ring forming with a diameter of 25-100mm, ensuring that the swing amplitude after hook installation is <1° through ±0.5mm precision control;
  • Shelf support strips: Flat wire bending forming, flatness <0.5mm, ensuring the flatness after shelf installation.
• Derivative applications:
  • Kitchen hangers: Such as pot lid racks, knife racks and other iron wire frames, realizing multi-category production through rapid mold change;
  • Industrial parts racks: Large iron wire frames below 700mm, meeting the needs of parts storage and transportation.

Ⅴ. Technical Specifications Table