2D Frame Bending and Butt Welding All-in-One Machine — Intelligent Molding Solution for Lighting Styling Industry

I. Analysis of Core Technical Architecture

(1) Intelligent Drive System

• Power Core Configuration
   Adopts Inovance IS620P series servo motors (wire-feeding axis 1.8kW + bending axis 1.0kW + cutting axis 1.0kW + servo lifting axis 1.0kW), paired with Yaqi high-precision planetary reducers, offering stable torque output (maximum bending torque 125N·m) and response speed at the 0.1ms level to ensure position control precision during high-speed operation.
   3D gearbox structure: Fully enclosed gear transmission design with SKF bearings and high-temperature lubricating grease, improving transmission efficiency to 98%, controlling noise below 75dB, and extending service life by 30% compared to traditional worm gear structures.
• Wire Feeding and Straightening System
   28-group straightening wheel matrix: Arranged in staggered upper and lower layers (14 upper + 14 lower), made of national standard Cr12 quenched material (hardness HRC62), surface mirror-polished (Ra≤0.2μm), capable of correcting wires with bend angles ≤15°, achieving straightness error ≤0.3mm/m after straightening.
   3 groups of active wire-feeding wheels: Driven by synchronous belts, each group equipped with pressure sensors to automatically adjust clamping force, suitable for round wires (φ3-8mm), flat wires (3×5-8×12mm), and square wires (3×3-8×8mm). Wire-feeding speed is steplessly adjustable from 0-25m/min, with repeat positioning accuracy of ±0.2mm.

(2) Precision Molding System

• Bending Mold Technology
   Core mold material: Bending punch and die use imported Japanese SKD11 tool steel (carbon content 1.5%, chromium content 12%), treated with 1050℃ vacuum quenching + three-time tempering, surface hardness HRC62±2, wear resistance increased by 40% compared to ordinary Cr12 molds, suitable for high-strength bending of 8mm iron wires.
   Motion control logic: Supports 180° vertical bending (inner mold stroke 50mm) and 360° rotational bending (outer mold servo indexing, minimum indexing angle 0.1°). Multi-axis linkage is achieved via a 32-bit PLC controller, allowing editing of 300 independent action combinations to meet complex curve forming such as "L-shaped", "U-shaped", and "Ω-shaped".
• Upgraded Welding Module
   63KW medium-frequency welding transformer: Adopts IGBT inverter technology, with output current stability ±1%, welding time control precision 1ms, paired with 2 sets of pneumatic clamps (clamping force adjustable 500N), achieving uniform penetration in iron wire butt welding, with weld tensile strength ≥85% of base metal.
   Automatic weld inspection: Optional laser vision sensor (precision ±0.1mm) real-time monitors welding position deviation, automatically corrects bending compensation, increasing yield rate to 99.2%.

(3) Intelligent Control System

• Human-Machine Interface
   10.4-inch color touchscreen: Supports Chinese-English bilingual switching, built-in with 300+ lighting frame molding templates (including common size databases). Novices can quickly configure production plans via "parameter wizard"; professional users can enter "advanced programming mode" to customize over 200 parameters such as bending angle, wire-feeding length, and welding current.
   4000-group program storage: Each program supports 300 action nodes, equipped with USB and Ethernet ports for batch program import/export, meeting fast changeover needs for multi-variety small-batch production (changeover time ≤5 minutes).
• Industrial-Grade Control Hardware
   Uses Mitsubishi FX5U series PLC (32-bit RISC processor, operation speed 0.065μs/basic instruction), paired with high-speed counting module (input frequency 200kHz), real-time collecting servo encoder position signals (resolution 24-bit 16,777,216 pulses/revolution), achieving position error ≤0.01mm under closed-loop control.
   Fault diagnosis system: Built-in with 128 types of abnormal status detection (e.g., mold overload, low air pressure, wire breakage), dual alarm via tricolor warning lights and screen pop-ups, supporting historical fault record query (storage period 6 months), average fault repair time shortened to 15 minutes.
  

II. Core Performance Indicators Comparison

III. Analysis of Typical Application Scenarios

(1) Standardized Lighting Frame Production

• Processing Flow: Automatic wire feeding (length 200mm) → five-wheel straightening (removing wire curvature) → servo cutting (error ±0.3mm) → four 90° bends (inner corner R5mm) → diagonal welding (welding time 200ms) → automatic unloading
• Production Data: Single cycle time 6 seconds, yield rate 99.5%, daily output (10 hours) 8,000 pieces, efficiency increased by 4 times compared to traditional manual bending + manual welding.

(2) Customized Production of Special-Shaped Parts

• Technical Implementation: Controls 360° rotation of outer mold via "arc interpolation algorithm", combined with adjustable inner mold bending depth (0-30mm) to achieve precise R150mm arc forming; welding module uses oscillating welding process to ensure uniform welds at arc joints.
• Programming Feature: Calls built-in "curve generation tool", automatically generates bending paths by inputting radius parameters, no need for manual node coordinate calculation, programming time shortened by 70%.

IV. Reliability Design and Maintenance System

(1) Mechanical Structure Reinforcement

• Machine Body Design: Adopts 8mm thick steel plate welded frame, stress-relieved by annealing, paired with adjustable leveling brackets for anchor bolts, vibration amplitude ≤0.05mm/s (no-load operation).
• Pneumatic System: 9 groups of AirTAC standard cylinders (bore φ32-φ63mm) paired with 5 SMC solenoid valves, air inlet equipped with three-stage filtration (water/oil/dust removal), ensuring pneumatic component life ≥3,000,000 cycles.

(2) Maintenance System

• Regular Maintenance Points:
   Mold Lubrication: Apply high-temperature lithium-based grease weekly (recommended Klüber GBB 2), keep mold sliding surfaces clean.
   Servo Motors: Inspect encoder connection cables quarterly, replace reducer lubricating grease annually.
   Electrical System: Clean control cabinet dust monthly, check terminal tightness.
• Wear Part Replacement Cycles:
   Wire-feeding Wheels: Normal use 12 months (adjusted according to wire surface roughness).
   Welding Electrodes: Replace every 5,000 welds (recommended chromium-zirconium copper electrodes).