2D Wire Bending Machine: Automated Forming Solution for Wall-Mounted Hooks

Ⅰ. Equipment Overview

Equipment Name: 2D Wire Bending Machine

Industry Positioning: Specifically designed for wall-mounted hooks, home hangers, and other iron wire products, integrating 3-axis servo drive and automated wire bending technology to achieve full-process precision forming of 2-6mm iron wires from feeding to finished hooks. Aiming at the strict requirements of wall-mounted hooks for installation precision and load-bearing strength, the equipment solves pain points such as large arc deviation and low efficiency in traditional manual wire bending with ±0.5mm-level precision and a production speed of 10-15 pieces/min, becoming the core equipment for large-scale production of home hardware.
Technical Core: Equipped with a 32-bit PLC control system and Yaqi servo system, supporting the storage of 10,000 groups of production data. It realizes flexible production of hook bodies, hanging rings, supports, and other components through 300 action combinations, adapting to various cross-sectional shapes such as round, flat, and square wires.

Ⅱ. Analysis of Core Technical Parameters and Performance

(1) Electrical and Power System

(2) Mechanical Forming System

• Straightening and Wire Feeding Components:
  • Number of straightening wheels: 18 groups, made of national standard Cr12 material, precision-machined with SKD11/51, hardness 58-62°, ensuring the straightness error of iron wires is <0.3mm;
  • Number of wire feeding wheels: 3 groups, Cr12 with fine polishing and heat treatment (hardness 58°), supporting universal feeding of 2-6mm round/flat/square wires, smooth and non-slip.
• Bending and Cutting Mechanisms:
  • Bending molds: 18 groups of adjustable molds (Cr12 material, hardness 58-62°), supporting up/down movement and 360° rotation of inner/outer molds, realizing the forming of complex shapes such as U-bends, right-angle bends, and barbs of hooks;
  • Cutting system: 1.0kW servo-driven cutter, suitable for cutting 2-6mm iron wires, with a cut perpendicularity ≤1° and no burrs, meeting the surface finish requirements of home products.
• Pneumatic Auxiliary System:
  • Number of cylinders: 3, number of solenoid valves: 4, 0.6MPa pressure drives actions such as feeding, discharging, and positioning, with a response time <50ms and process synchronization precision of ±0.2mm.

(3) Precision and Efficiency Indicators

• Production efficiency: 10-15 pieces/min (standard wall-mounted hooks), reaching 20-25 pieces/min for a 200*200mm square frame, which is 5-8 times higher than traditional manual efficiency;
• Forming precision:
  • Bending precision ±0.5mm, ensuring the consistency of hook arcs;
  • Wire feeding precision ±0.5mm, ensuring the fit of hook opening sizes;
  • Flatness <0.5mm, meeting the flatness requirements for wall-mounted installation.

Ⅲ. Core Advantages of the Equipment

1. Flexible production capability:

• Supports the forming of hooks with 2-6mm wire diameters and any arc. Through the storage of 10,000 groups of data and 300 action combinations, it can quickly switch hook specifications (such as 3mm small hooks and 6mm load-bearing hooks), with a model change time <3 minutes;
• Compatible with materials such as Q235 carbon steel and galvanized iron, meeting the anti-rust and load-bearing performance requirements of home hardware.

2. Intelligent control and operational convenience:

• Chinese/English bilingual system, touch screen + button dual-operation mode, supporting production data upload and download. Novices can take up their posts after 1 hour of training;
• Real-time monitoring of parameters such as bending angle and wire feeding length, automatic alarm and shutdown in case of abnormalities, with a rejection rate ≤0.5%.

3. Energy saving and durability:

• Total power 4.8kW, 40% more energy-saving than traditional equipment. With a heat dissipation system, the temperature of core components is ≤65℃, and the continuous operation life of the equipment exceeds 80,000 hours;
• The mold life exceeds 100,000 times. Cr12 alloy material reduces maintenance costs, saving an average of 12,000 yuan in consumable expenses annually.

Ⅳ. Application Scenarios: Full Category Coverage of Wall-Mounted Hooks

• Standard hook production:
  • Forming of 2-4mm wire diameter wall-mounted hook bodies, ensuring the uniformity of hook opening sizes through ±0.5mm precision control, adapting to different wall installation hole distances;
  • 180° bending combined with a 360° rotating die head realizes the barb process at the hook tail, with a load-bearing capacity of more than 5kg to prevent hangings from falling off.
• Functional component processing:
  • Hanging ring components: Small ring forming with a diameter of 25-100mm, used for connecting hooks and hangings, with flatness <0.5mm;
  • Supports: Flat wire bending forming, supporting multi-layer hook combination installation, increasing structural stability by 30%.
• Derivative applications:
  • Decorative hooks: Special-shaped hooks such as wavy and heart-shaped ones, realizing customized production through rapid mold change;
  • Industrial shelf hooks: 6mm wire diameter large load-bearing hooks, meeting the needs of workshop tool hanging, with a single-point load-bearing capacity ≥10kg.
    

Ⅴ. Technical Specifications Table