2D Frame Bending & Butt Welding Machine: Intelligent Integrated Solution for Shelving Automated Production

Core Positioning of the Equipment

A high-precision 4-axis integrated machine developed for the shelving industry, integrating wire straightening, fixed-length cutting, frame bending, and automatic butt welding. It realizes fully automated "forming + welding" for 3-8mm iron wires (round/flat/square), breaking through the efficiency bottleneck of traditional manual bending and welding. Equipped with Inovance servo system and Yaqi control system, it provides one-stop production solutions from wire to finished products for warehouse racks, household shelves, etc., adapting to the modern manufacturing needs of "multi-specification and fast delivery".

Technical Parameters at a Glance

Three-Dimensional Technological Innovations and Shelving Adaptation Advantages

1. Precision Forming Driven by Servo System
   • Inovance Servo Power Chain: 4.0kW feeding servo paired with a planetary reducer delivers 125N·m torque, ensuring non-slip high-speed feeding for 8mm iron wires, with feeding stability improved by 40% compared to traditional equipment. The 1.8kW bending servo supports 360° rotation of the outer die, enabling one-time forming of L/U-shaped shelving frames, with a 90° bending angle deviation ≤±0.3° to ensure the verticality of shelf panel installation.
   • Three-Stage Bending Process: Preset parameter libraries for 3-8mm wires, with material elongation ≥20% at 6mm wire bends to avoid skeleton cracking, meeting the industry standard of shelving load-bearing ≥80kg/layer.
2. Efficient Integration of Welding Module
   • 63KVA High-Frequency Butt Welding System: Synchronously welds frame joints after bending, with solder joint diameter φ2-3mm and uniform depth, eliminating the need for secondary welding. Taking a 200×200mm square frame as an example, a single cycle (bending + welding) takes 6-8 seconds, 2.5 times more efficient than "manual bending + welding".
   • Dual Robotic Clamps: Automatically completes feeding, positioning, and welding, reducing manual intervention. The welding pass rate increases from 85% to 99.2%, eliminating hidden dangers of virtual welding and missed welding.
3. Flexible Production Data Management
   • Rapid Call of 4,000 Process Libraries: Stores mainstream specification parameters for household shelving (400×300mm shelf panels) and warehouse racks (1200×500mm columns), with historical orders retrievable in 3 minutes and model changeover debugging time ≤10 minutes, adapting to e-commerce "small-batch, multi-batch" order needs.
   • Graphical Programming Interface: Built-in shelving frame graphic libraries, generating bending paths via drag-and-drop without coding, boosting proofing efficiency by 70% compared to traditional mold testing and reducing technical thresholds.

Comprehensive Analysis of Production Processes

1. Wire Pretreatment Process
   • 9-Roller Straightening System: 0.5MPa light pressure for 3mm thin wires and 1.2MPa segmented heavy pressure for 8mm thick wires, with straightness controlled within 0.1mm/m and no surface indentation, ensuring uniform frame arcs after bending.
   • Oblique Blade Cutting Process: 1.0kW cutting servo drives a 10° blade, with 8mm iron wire cutting force stabilized at 20kN, end surface roughness Ra≤25μm, and burr-free cuts, allowing direct entry into the welding process.
2. Typical Forming Case (5mm Iron Wire Shelving Square Frame)
   1. Feeding servo conveys 600mm wire → 9-roller straightening → outer die rotates to 0° for positioning;
   2. Bending servo drives the outer die to rotate 90° clockwise, while the feeding servo feeds 400mm synchronously to complete the first-side bend;
   3. Repeat bending three times to form a square frame, and the welding module automatically butt-welds the joints;
   4. Robotic arm transfers the finished product, with a single cycle of 7.2 seconds, diagonal error ≤±0.5mm, and welding gap ≤0.8mm.
3. Quality Control System
   • Online Laser Detection: 12μm precision micrometer scans bending angles and welding misalignments in real time, automatically calibrating when deviations >0.5° to ensure verticality ≤1° after shelving installation.
   • Load-Bearing Simulation Test: 100kg static pressure test on 8mm iron wire frames, with no deformation at bends, complying with GB/T 28576 warehouse rack load-bearing standards.

Application Scenarios and Benefit Analysis

1. Large-Scale Production Scenario (Case of a Warehouse Rack Enterprise)
   1. Configuration: 3 machines + automatic sorting line
   2. Specification: 800×500mm warehouse frame (6mm iron wire)
   3. Capacity: Single machine daily output 4,800 pieces, 3 machines monthly output >300,000 pieces, meeting urgent order needs of logistics warehouses
   4. Cost: Labor cost reduced from ¥1.8/piece to ¥0.5/piece, annual savings of ¥1.8 million
   5. Quality: Diagonal error reduced from ±1.2mm to ±0.5mm, welding defect rate reduced from 7% to 0.8%
2. Customized Flexible Production (Case of an E-Commerce Home Brand)
   1. Rapid Model Change: Switch between 3mm household wires and 8mm commercial wires molds in 15 minutes, supporting the e-commerce "48-hour proofing - 72-hour mass production" model.
   2. High-Value-Added Processing: Customized arc frames, achieving gradient arc bending through 300 action combinations, increasing product premium by 50% to adapt to high-end shelving needs.

Intelligent Control System and Industrial Design

1. Electrical System
   • Intelligent Power Distribution: 32-bit PLC monitors 7.8kW power in real time, automatically adjusting servo compensation when the welding module is overloaded, adapting to 380V±15% power grid fluctuations.
   • Dual-System Operation: Button + touch screen dual mode, supporting offline programming, with production line workers mastering operation within 2 hours.
2. Mechanical Structure
   • Heavy-Duty Body: HT300 cast iron base (2600×1300mm), 1100KG weight ensures no vibration during 8mm wire bending, with stability improved by 30%.
   • Low-Noise Heat Dissipation: Independent air cooling for servos, maintaining ≤65℃ after 48 hours of continuous operation, noise ≤75dB, complying with industrial environmental standards.