2D Frame Bending and Welding Integrated Machine: A Benchmark for Efficient Forming in Medical Instrument Sterilization Basket Production

In the field of medical device supporting facilities, medical instrument sterilization baskets, as key carriers ensuring the cleanliness and safety of medical instruments, have strict requirements for production precision, structural stability, and material adaptability. The corrosion resistance of stainless steel, uniform grid structure, and precise dimensional tolerances directly affect the service life and medical compliance of sterilization baskets. The emergence of the 2D Frame Bending and Welding Integrated Machine, with its integrated solution of "high-precision forming + efficient welding", has become a core equipment for the medical instrument sterilization basket industry to break through traditional production bottlenecks.

The production of medical instrument sterilization baskets first faces the challenge of "precision and consistency". Traditional manual bending or split-type equipment processing often leads to skewed basket frames and uneven grid spacing due to manual operation errors, which not only affects aesthetics but also may cause instrument jamming due to gap deviations, violating the safety requirements for medical instrument storage. The 2D Frame Bending and Welding Integrated Machine solves this pain point from the source with its solid parameters.

Its bending accuracy is controlled within ±0.5mm, and the wire feeding accuracy is also stable at ±0.5mm, meaning that every angle and every section of wire in both the frame bending and internal grid forming of the sterilization basket can strictly conform to design standards. Behind this precision is the sophisticated collaboration of the equipment's 28 sets of national standard Cr12 material straightening wheels — after precision machining and heat treatment, these straightening wheels, with a hardness of 62HRC, can accurately straighten stainless steel round wires, flat wires, and square wires within the range of 3-8mm, avoiding forming deviations caused by wire bending.

To meet the demand for "batch production with efficiency", the equipment achieves a production capacity breakthrough with a speed of 10-15 pieces per minute (based on 200*200mm square frames). This efficiency stems from the collaboration of multiple power systems: a 3.8kw wire feeding motor ensures smooth wire delivery, a 1.5kw bending motor drives the mold to complete angle adjustments within ±180° at a speed of approximately 100 rpm, and a 1.0kw cutting motor provides precise cutting. This allows the entire process from wire feeding to forming to be completed without manual intervention, significantly outperforming the production rhythm of traditional equipment.

Medical instrument sterilization baskets come in various specifications, ranging from conventional instrument storage baskets to customized precision instrument sterilization racks, with significant differences in shape and size. This places high demands on the equipment's "flexible production capability". The 2D Frame Bending and Welding Integrated Machine achieves flexible "one-click specification switching" through its intelligent control system.

The equipment is equipped with a 32-bit high-performance PLC processor, supporting 4000 sets of data storage, with each set containing up to 300 action settings. This means that when producing sterilization baskets of different sizes and grid densities, there is no need to repeatedly adjust the mechanical structure. By calling preset programs, it can combine multiple frame shapes such as square, rectangular, and special-shaped through composite actions of "inner mold up/down movement + outer mold up/down movement + 360° clockwise/counterclockwise rotation". Combined with the "button + touch screen" dual operating system, even complex basket corner and folding designs can be quickly realized through visual programming, greatly reducing changeover time.

What is more noteworthy is its "Chinese-English bilingual system + upload/download function", which not only facilitates quick mastery by domestic and foreign operators but also supports cloud synchronization and traceability of production data. In response to the medical industry's regulatory requirement of "traceable production records", this function can accurately record the processing parameters of each batch of sterilization baskets, providing data support for quality control.

The service life of a sterilization basket largely depends on the firmness of the frame welding. Welding stainless steel requires overcoming the contradiction between "high-temperature deformation" and "insufficient welding strength", and the welding module of the 2D Frame Bending and Welding Integrated Machine provides a professional solution for this.

The equipment is equipped with a 63KW high-power welding transformer, which can instantly generate a stable welding current to ensure sufficient fusion at the stainless steel wire joints, forming uniform, non-porous welds. At the same time, the collaborative action of 2 sets of mechanical grippers can accurately fix the workpieces to be welded, avoiding joint misalignment caused by displacement during welding. This combination of "strong current + stable clamping" ensures that the welded parts of the sterilization basket frame can withstand repeated high-temperature sterilization and frequent collisions during instrument storage, significantly extending the product's service life.

The production of medical device accessories often requires equipment to maintain long-term stable operation, and the 2D Frame Bending and Welding Integrated Machine's durability design is also tailored to industry needs. Its core components are made of high-hardness, wear-resistant materials: the wire feeding wheels are made of national standard Cr12, with a hardness of 58HRC after precision polishing and heat treatment, ensuring a smooth surface even after long-term delivery of hard stainless steel wires, avoiding wire scratches; the bending molds are made of high-quality die steel such as SKD11/51, ensuring resistance to deformation during high-frequency bending actions and maintaining precision stability.

The overall dimensions of the equipment are 2400*1250*1500, and its weight of 1100KG not only ensures stability during operation but also facilitates workshop layout planning. The pneumatic system configuration of 9 cylinders and 5 solenoid valves provides sufficient power for various mechanical actions, combined with a bending torque of approximately 125 Nm, enabling smooth bending even when processing 8mm thick stainless steel wires without worrying about equipment overload.

For the medical instrument sterilization basket industry, the value of the 2D Frame Bending and Welding Integrated Machine lies not only in "leading parameters" but also in its precise solution to industry pain points. Its wide adaptability to stainless steel materials (covering wire diameters of 3-8mm and compatible with multiple cross-sections such as round, flat, and square) meets the demand for basket strength in different sterilization scenarios — for example, heavy-duty sterilization baskets used in operating rooms require 8mm wires to ensure load-bearing capacity, while conventional instrument baskets can use 3-5mm wires to reduce costs.

The automated production process fundamentally reduces manual contact, lowering the risk of rust caused by hand oil contamination on the stainless steel surface, and indirectly improving the hygiene level of sterilization baskets. At the same time, efficient production capacity and stable qualification rates help enterprises gain an advantage in the cost competition of medical consumable procurement, achieving the dual benefits of "quality improvement" and "cost reduction".

From precision forming to strong welding, from flexible customization to stable durability, the 2D Frame Bending and Welding Integrated Machine has redefined the production standards of medical instrument sterilization baskets with its full-dimensional performance advantages. It is not only an efficient processing equipment but also a core driving force for promoting the upgrading of the medical supporting industry towards "standardization, intelligence, and high quality", building the first line of defense at the production end for the safety guarantee system of medical instruments.