2D Wire Bending, Frame Bending and Welding Integrated Machine: An All-Round Intelligent Manufacturing Equipment for Basket Production

In the production field of various iron wire baskets, ranging from household storage baskets to industrial turnover baskets, the versatility and precision of equipment directly determine production efficiency. The 2D wire bending, frame bending and welding integrated machine, relying on modular design and intelligent control, has become the core equipment covering the production of multiple types of baskets. Its feature of integrating high-strength processing performance and flexible adaptation capability has redefined the large-scale production standards for iron wire basket products.

An Efficiency Engine for Multi-Category Production
With a basic production speed of 8-10 pieces per minute, this equipment has built an efficient basket manufacturing system. For 200*200mm standard square baskets, the efficiency can be increased to 10-15 pieces per minute. Calculated based on an 8-hour single shift, the daily production capacity can reach 7,200 pieces, which is equivalent to 3-4 times the output of traditional manual production lines. This high efficiency stems from the full-process collaborative design: a wire feeding speed of 25m/min ensures the continuous supply of 3-8mm iron wire raw materials, and a maximum bending speed of 100 revolutions per minute combined with 360° forward and reverse rotation functions can quickly complete the one-time forming of complex structures such as basket borders and handles. What's more noteworthy is its 4,000 sets of data storage capacity, with each set containing 300 action combinations. Whether it is a round fruit and vegetable basket, a square storage basket or a special-shaped industrial basket, minute-level production change can be achieved by calling preset programs, which greatly reduces the switching cost of multi-variety and small-batch production.

An Adaptation Expert for Full-Specification Wires
The equipment's full compatibility with 3-8mm iron wires enables it to meet the production needs of baskets with different strength requirements. 28 straightening wheels made of national standard Cr12 are precisely arranged to form a multi-stage straightening channel. Even for high-strength iron wires used in industrial baskets for storing heavy objects, the straightness can be controlled within ±0.5mm; 3 sets of wire feeding wheels are made of national standard 12 material, with a hardness of 58 after fine polishing and heat treatment, which can firmly clamp wires of different cross-sections such as round wires, flat wires and square wires, and avoid surface scratches that affect the appearance of products. In response to the common interface welding needs in basket production, the 63KW welding transformer can output stable current, making the fusion depth at the iron wire joints uniform, and the weld strength reaches more than 85% of the base metal, ensuring that the storage basket does not crack or deform during frequent use.

The Control Core with Micron-Level Precision
The 32-bit high-performance PLC processor equipped in the equipment constitutes the "intelligent brain" for precise production. Through the button + touch screen dual-system control panel, operators can intuitively set parameters such as bending angle and wire feeding length. Cooperated with the closed-loop control network composed of Yaqi servo system and 9 sets of cylinder solenoid valves, it achieves bending accuracy and wire feeding accuracy of ±0.5mm. This precise control is reflected in basket production as follows: the size error of baskets in the same batch is extremely small, and they fit tightly when stacked; the welding position deviation between the handle and the basket body does not exceed 0.5mm, ensuring balanced force. The independent up and down movement function of the inner and outer molds, combined with a maximum bending force of 125 Nm, can complete bending at any angle within 180°, easily realizing the arc transition or right-angle forming of basket corners. The alternating operation design of 2 sets of manipulator clamps further enables seamless connection between bending and welding processes, reducing manual intervention by more than 60%.

A Reliable Cornerstone for Industrial Production
The equipment has an external dimension of 2400*1250*1500, which can be flexibly integrated into the existing production line layout. The total weight of the machine is 1100KG, combined with shockproof design, to ensure stability during high-speed operation. The electrical system adopts a three-phase 380V + grounding wire configuration, and the reasonable distribution of the total power of 7.3KW (3.8KW for wire feeding + 1.5KW for bending + 1.0KW for cutting + 1.0KW for servo lifting) not only ensures sufficient power for each executive component but also avoids energy waste. The bending die is precision-machined with high-quality SKD11/51 materials, with a hardness of 62. In continuous production of 16 hours per day, its service life can reach more than 100,000 times, greatly reducing the frequency of replacing vulnerable parts. The Chinese-English bilingual control system supports program upload and download, facilitating parameter unification during collaborative production of multiple devices, and is especially suitable for standardized management of large-scale basket production enterprises.

Through the integrated process of "wire feeding - straightening - bending - welding - forming", this equipment compresses the 7-8 processes of traditional basket production into a single equipment automated operation. Its ability to be compatible with multi-specification wires, quickly switch between multi-variety products and perform high-precision processing not only saves enterprises a lot of labor and site costs but also enhances market competitiveness through stable product quality, becoming a key equipment for the transformation of iron wire basket production from manual manufacturing to intelligent manufacturing.