2D Frame Bending and Butt Welding Machine: High-Efficiency Intelligent Manufacturing Solution for Triangular Bathroom Racks

一、Equipment Overview

Equipment Name: 2D Frame Bending and Butt Welding Machine

Industry Positioning: Specifically designed for iron frame products such as triangular bathroom racks and bathroom accessories, integrating automated wire bending and high-frequency welding processes to achieve full-process closed-loop production of 3-8mm iron wires from feeding to finished frames. Aiming at the strict requirements of bathroom racks for load-bearing strength and anti-rust performance, the equipment solves the pain points of frame deformation and virtual soldering in traditional manual bending and welding with ±0.5mm-level precision and a production speed of 8-10 pieces/minute, becoming the core equipment for large-scale production of bathroom hardware.
Technical Core: Equipped with a 32-bit PLC control system and Yaqi servo system, supporting the storage of 4,000 sets of production data. It realizes flexible production of components such as the main frame, hooks, and shelf supports of triangular bathroom racks through 300 action combinations, and achieves high-strength solder joint forming with a 63KW welding transformer.

二、Analysis of Core Technical Parameters and Performance

（一）Electrical and Power System

（二）Mechanical Forming System

• Wire Feeding and Straightening Assembly:
  • Number of wire feeding wheels: 3 groups, made of Cr1MOV wear-resistant material, supporting universal feeding of round/flat/square wires (3-8mm), with stable wire feeding without slipping, adapting to the production of support bars with different cross-sections for bathroom racks.
  • Straightening mechanism: Multiple groups of straightening wheels combined with servo drive ensure the straightness error of iron wires <0.3mm, laying the foundation for the right-angle precision of triangular frames.
• Bending and Welding Mechanism:
  • Bending mold: 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 the hypotenuse and right-angle side of triangular bathroom racks.
  • Manipulator clamps: 2 sets of pneumatic clamps, positioning accuracy ±0.2mm, completing frame butt welding with the welding transformer, with smooth and burr-free solder joints, meeting the surface finish requirements of bathroom products.
• Cutting and Auxiliary System:
  • Cutter motor cutting force: Suitable for cutting 3-8mm iron wires, with a cut verticality ≤1°, ensuring the interface fitting degree during triangular rack splicing.
  • Pneumatic system: 9 cylinders + 5 solenoid valves, driven by 0.6MPa pressure for actions such as feeding, retreating, and welding, with a response time <50ms and process synchronization accuracy of ±0.3mm.

（三）Precision and Efficiency Indicators

• Production Efficiency: 8-10 pieces/minute (standard triangular bathroom racks), 10-15 pieces/minute for 200*200mm square frames, with an efficiency improvement of more than 6 times compared to traditional manual work.
• Forming Precision:
  • Bending accuracy ±0.5mm, ensuring the diagonal error of the triangular frame <1mm, and the wall fit after installation ≥98%.
  • Wire feeding accuracy ±0.5mm, ensuring the splicing precision of shelf support bars and the main frame.
  • Solder joint position accuracy ±0.3mm, meeting the strength consistency requirements of the load-bearing structure of bathroom racks.

三、Core Advantages of the Equipment

1. Flexible Production Capability:
   • Supports frame forming with a perimeter range of 30-700mm. Through 4,000 sets of data storage and 300 action combinations, it can quickly switch between products such as single-layer/double-layer structures of triangular bathroom racks and hooks of different sizes, adapting to the needs of various triangular angles such as 90°/120°.
   • Compatible with materials such as Q235 carbon steel and galvanized iron, and can pass the 240-hour salt spray test after surface treatment, meeting the anti-rust requirements of bathroom environments.
2. Intelligent Control and Visual Operation:
   • Chinese/English dual-language system, touch screen + button dual-operation mode, supporting production data upload/download. Newcomers can start working 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 less than 1% and decreasing the after-sales maintenance cost of bathroom racks.
3. Energy Saving and Durability:
   • Total power 7.8kW, 35% more energy-saving than traditional equipment. Combined with a water cooling system, the temperature of core components ≤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 over 150,000 times, and the annual maintenance cost is reduced by 15,000 yuan, suitable for mass production scenarios of bathroom racks.

四、Application Scenarios: Coverage of All Processes of Triangular Bathroom Racks

• Main Frame Forming:
  • Triangular frame coiling and welding with a side length of 300-600mm as the main support of the bathroom rack, with a single-point load-bearing capacity of more than 15kg, meeting the needs of multi-layer storage.
  • Bending angle of 180° combined with a 360° rotating mold head to realize the edge flanging process of the frame, preventing hand scratching and enhancing structural strength, adapting to long-term use in bathroom humid environments.
• Functional Component Processing:
  • Hook components: Small ring forming with a diameter of 25-100mm. Through ±0.5mm precision control, the swing amplitude after hook installation is <1°, preventing towels from slipping.
  • Shelf support bars: Flat wire bending forming, with a flatness <0.5mm, ensuring the flatness after the installation of glass/metal shelves and avoiding item dumping.
• Derivative Applications:
  • Bathroom accessories: Special-shaped parts such as triangular baskets and corner racks, realizing multi-category production through rapid mold change.
  • Kitchen storage racks: Iron wire frames below 700mm, meeting the needs of products such as spice racks and pot lid racks, expanding the enterprise's product line.
    

五、Technical Specifications Table