2D Wire Bending Machine: Intelligent Forming Solution for Fruit and Vegetable Baskets

Core Positioning of the Equipment

A high-precision 4-axis machine developed specifically for the automated production of fruit and vegetable baskets, integrating full-process functions of wire feeding, straightening, cutting, and bending. It enables efficient forming of basket skeletons, handles, bottom frames, and other components for 2-6mm iron wires (round/flat/square). Through the precise coordination of ORIENTAL servo system and Yaqi control system, it addresses the pain points of low efficiency and poor precision in traditional manual wire bending, providing a one-stop intelligent manufacturing solution from wire to finished products for fresh produce baskets and fruit/vegetable storage containers, meeting the modern supermarket and e-commerce supply chain demands for "multi-specification and fast delivery".

Technical Parameters at a Glance

Three-Dimensional Technological Innovations and Fruit/Vegetable Basket Adaptation Advantages

1. Precision Mold System Design
   • 18 Sets of Cr12 Straightening Wheels: Adopt progressive pressure adjustment to achieve 0.05mm/m straightness control for 2mm thin wires. For 6mm thick wires, eliminate internal stress through segmented heavy pressure, ensuring scratch-free surfaces and uniform arcs on basket skeletons, meeting the appearance flatness requirements of fruit/vegetable baskets (e.g., basket bottom frame warpage ≤1mm).
   • SKD11 Bending Molds: 经过 51 finishing processes with hardness reaching 58-62HRC, capable of withstanding over 100,000 bending cycles. Ideal for complex structures such as curved handles and oval baskets, ensuring crack-free 180° continuous bending for fresh produce baskets and handle load-bearing capacity ≥5kg.
2. Servo-Driven Precision Forming
   • ORIENTAL Servo Power Chain: 2.3kW feeding servo paired with planetary gear reducer maintains ±0.5mm precision at 90m/min feeding speed, ensuring basket frame perimeter tolerance ≤±0.2mm for seamless stitching with mesh fabrics. The 1.5kW bending servo supports 360° outer die rotation for one-time forming of L/U-shaped basket frames with angle deviation ≤±0.3°.
   • Three-Stage Bending Process: Preset parameter libraries for 2-6mm wire differences, ensuring material elongation ≥22% at 4mm wire bends to prevent skeleton fractures and guarantee basket load-bearing capacity ≥15kg (suitable for loading ~10kg of fruits/vegetables).
3. CAD-Driven Flexible Production
   • Graphical Programming Interface: Built-in fruit/vegetable basket frame graphic libraries (e.g., round fruit baskets, rectangular vegetable baskets) allow designers to directly import AutoCAD models to generate bending programs, eliminating traditional mold testing. For example, custom oval strawberry basket skeletons can be automatically formed via CAD-preset trajectories, reducing single-piece forming time by 70% compared to manual operations.
   • 10,000 Process Libraries: Store full-series specification parameters for supermarket standard baskets (300×200mm) and e-commerce express baskets (400×300mm). Historical orders can be recalled in 3 minutes with model changeover time ≤10 minutes, adapting to seasonal order demands for "multi-specification, small-batch" fruit/vegetable baskets (e.g., rapid switching between strawberry and citrus season-specific baskets).
     

Comprehensive Analysis of Production Processes

1. Wire Pretreatment Process
   • Straightening Process: 18 sets of straightening wheels with three-stage pressure adjustment (light→medium→heavy). 2mm wires use 0.3MPa light pressure, while 6mm wires use 1.0MPa heavy pressure, achieving final straightness ≤0.08mm/m to ensure uniform basket frame arcs and prevent deformation.
   • Cutting Process: 15° oblique blade cutter with 1.0kW servo ensures cutting end surface roughness Ra≤12.5μm. Optional burr removal program prevents scratching of fruits/vegetables.
2. Typical Forming Case (4mm Iron Wire Vegetable Basket Frame)
   1. Feeding servo conveys 1200mm wire → 18 sets of straightening wheels for secondary straightening → outer die rotates to 0° for positioning;
   2. Bending servo drives outer die to rotate 90° clockwise while feeding servo feeds 400mm uniformly to complete the first bend;
   3. Repeat three more bends to form a square frame, cutter servo cuts the wire, and the finished product is transferred to the shaping station by a robotic arm;
   4. Single cycle time: 3.2 seconds, 5 times more efficient than manual operations, with square diagonal error ≤0.8mm, meeting stacking verticality requirements (≤1°).
3. Quality Control System
   • Load-Bearing Test: 20kg static pressure test on 6mm iron wire baskets shows no deformation at bends, meeting supermarket fruit/vegetable basket load standards (typically 10-15kg).
   • Salt Spray Corrosion Test: After 48-hour salt spray testing (simulating humid fresh produce areas), surface rust coverage ≤3%, suitable for wet environments like supermarket refrigerators and wholesale markets.
     

Application Scenarios and Benefits in Fruit/Vegetable Basket Production

1. Large-Scale Supermarket Supply Scenario (Case of a Fresh Produce Chain)
   • Equipment Configuration: 2× 2D wire bending machines + automated welding line
   • Production Spec: 350×250mm vegetable basket frames (4mm iron wire)
   • Capacity Data: Single machine daily output 9,600 pieces; 2 machines meet monthly demand of 500,000 baskets
   • Cost Optimization: Labor cost reduced from ¥1.5/piece to ¥0.4/piece, saving ¥1.32 million annually
   • Quality Improvement: Frame diagonal error reduced from ±1.2mm to ±0.5mm; assembly pass rate increased from 85% to 99.3%
2. E-Commerce Customized Flexible Production (Fruit/Vegetable Gift Box Case)
   • Rapid Model Change: Switch between 2mm strawberry gift baskets and 6mm citrus transport baskets in 10 minutes via 10,000 data sets, supporting e-commerce "72-hour proofing - 5-day mass production" delivery.
   • High-Value-Added Processing: Custom wavy basket frames for premium gift boxes through 300-action gradient bending programs, increasing product premium by 60% compared to standard baskets.

Intelligent Control System and Industrial Design

1. Electrical System Configuration
   • Anti-Interference Design: Dual-filter control circuit ensures stable operation under 380V±15% power fluctuations, suitable for complex factory power environments. PLC supports offline programming to prevent data loss.
   • Intelligent Material Break Response: Real-time wire feeding monitoring triggers automatic shutdown and alarm within 0.5 seconds, reducing wire waste (~800kg/year per machine).
2. Mechanical Structure Optimization
   • Compact Design: 2300×1100mm footprint fits factory layouts; 650KG weight allows flexible relocation for integrated "bending-welding-spraying" production.
   • Low-Noise Cooling System: Independent air-cooled servo motors maintain ≤65℃ after 48-hour continuous operation with noise ≤72dB (1m), meeting food factory environmental standards.

Industry Value Summary