2D Wire Bending Machine: Intelligent Forming Solution for Lighting Fixture Skeletons
2025-06-06
Core Positioning of the Equipment
A 4-axis high-precision machine specifically developed for the automated production of lighting fixture skeletons. It integrates feeding, straightening, cutting, and bending functions, supporting high-speed processing of 2-6mm iron wires (round, flat, or square). Through the precise coordination of 18 sets of Cr12 straightening wheels and SKD11 bending dies, combined with 300 motion combinations driven by a CAD module, it enables diverse forming of skeletons for chandeliers, wall lamps, table lamps, etc., providing lighting enterprises with a one-stop intelligent manufacturing solution from design to mass production.
![2D Wire Bending Machine: Intelligent Forming Solution for Lighting Fixture Skeletons 1]()
A 4-axis high-precision machine specifically developed for the automated production of lighting fixture skeletons. It integrates feeding, straightening, cutting, and bending functions, supporting high-speed processing of 2-6mm iron wires (round, flat, or square). Through the precise coordination of 18 sets of Cr12 straightening wheels and SKD11 bending dies, combined with 300 motion combinations driven by a CAD module, it enables diverse forming of skeletons for chandeliers, wall lamps, table lamps, etc., providing lighting enterprises with a one-stop intelligent manufacturing solution from design to mass production.
Quick Overview of Technical Parameters
| Parameter Category | Technical Specifications |
|---|---|
| Production Efficiency | Standard Output: 8-10 pieces/min High-Efficiency Mode: 20-25 pieces/min (tested with 200×200mm square frames) |
| Wire Processing | Material: Iron Diameter: 2-6mm Applicable Types: Round / Flat / Square wires (fully compatible with all metal wires) |
| Power System | Total Power: 5.8kW + 1.0kW Servo Configuration: 2.3kW Feeding Servo + 1.5kW Bending Servo + 1.0kW Cutting Servo + 1.0kW Lifting Servo |
| Mechanical Configuration | Straightening Wheels: 18 sets of Cr12 (hardness 58-62HRC) Feeding Wheels: 3 sets of Cr12 (precision polished, hardness 58HRC) Bending Dies: SKD11 (hardness 58-62HRC) |
| Motion Performance | Feeding Speed: Max. 90m/min Bending Speed: 300 rotations/min (180°) Motion Direction: Up-down movement of inner/outer dies + 360° rotation of outer die |
| Precision Indicators | Bending Precision: ±0.5mm Feeding Precision: ±0.5mm |
| Equipment Specifications | Dimensions: 2300×1100×1650mm Weight: 650KG |
| Intelligent System | Storage: 10,000 sets of data (300 actions per set) Control: 32-bit processor + CAD module + Chinese-English touch screen |
3D Technological Innovation and Lighting Adaptation Advantages
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Precision Design of the Die System
- Straightening System: 18 sets of national standard Cr12 straightening wheels with progressive pressure adjustment. For 2mm thin wires, it achieves a straightness control of 0.05mm/m. For 6mm thick wires, it eliminates internal stress through segmented heavy pressure, ensuring scratch-free surfaces and uniform arcs on lighting fixture skeletons.
- Bending Dies: SKD11 material dies processed through 51 precision machining steps, with a hardness of 58-62HRC. They can withstand over 100,000 bending cycles, particularly suitable for complex structures such as arcs, loops, and polygons in lighting skeletons. For example, they enable 180° continuous bending of chandelier petal skeletons without cracks.
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CAD Module-Driven Flexible Production
- Built-in CAD graphic import function allows lighting designers to directly convert 3D models into bending programs, eliminating traditional mold testing. Examples:
- Chandelier Spiral Skeletons: Using pre-set spiral trajectories in CAD, the machine automatically performs 360° rotational bending + feeding linkage, reducing single-piece forming time by 70% compared to manual processing.
- Special-Shaped Wall Lamp Brackets: By recalling 10,000 sets of stored data, mold switching is completed within 10 minutes, enabling small-batch customized production.
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High-Speed Feeding and Dynamic Precision Control
- A 2.3kW ORIENTAL MOTOR servo drives a feeding speed of 90m/min, combined with real-time laser distance measurement calibration. The feeding error is ≤±0.5mm, meeting the requirement of tight joints in lighting skeletons (e.g., gaps ≤0.8mm when welding table lamp base frames).
- The four-axis linkage technology of the YAKI servo system maintains a material elongation rate of ≥22% at 90° bends of 6mm iron wires, preventing skeleton fractures that could affect lighting installation stability.
Comprehensive Analysis of Lighting Fixture Skeleton Production Processes
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Pretreatment and Forming Processes
1.1 Wire Pretreatment- Straightening Stage: 18 sets of straightening wheels with three-stage pressure adjustment (light pressure → medium pressure → heavy pressure). 2mm wires use 0.3MPa light pressure, while 6mm wires use 1.0MPa heavy pressure, achieving a final straightness control within 0.08mm/m.
- Cutting Process: A 15° oblique blade cutter Cooperate with a 1.0kW servo results in a cutting end surface roughness Ra≤12.5μm. For the precise cutting requirements of lighting skeletons, an optional burr cleaning program is available.
1.2 Typical Forming Case (4mm Iron Wire Chandelier Ring Skeleton)- CAD imports the circular trajectory → Feeding servo conveys 1200mm of wire → Straightening system performs secondary alignment.
- Outer die rotates to 0°, inner die moves up to position the starting point.
- Bending servo drives the outer die to rotate 360° clockwise while the feeding servo feeds the wire at a uniform speed.
- Cutting servo acts to cut the wire, and the finished product is transferred to the shaping station by a robotic arm. Single-cycle time: 3.2 seconds, 5 times more efficient than traditional manual ring bending, with a roundness error ≤0.8mm.
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Quality Control System
- Online Detection: A 12μm laser micrometer scans bending angles and arcs in real-time. When a deviation of >0.5° is detected in a table lamp arm, the system automatically rejects the part, ensuring a verticality ≤1° after installation.
- Durability Test: 6mm iron wire skeletons undergo 50,000 load-bearing tests (simulating lighting suspension), with a breaking load ≥80kg (industry standard ≥50kg), meeting safety requirements for chandeliers.
Intelligent Control System and Industrial Design
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CAD Integrated Control Module
- Graphical Programming: Supports direct import of AutoCAD and SolidWorks files. Bending paths are generated by dragging action blocks, allowing novice designers to master programming within 2 hours.
- Parameter Self-Learning: The system automatically records optimal bending parameters for different wire diameters. For newly designed special-shaped skeletons, parameter recommendation matching accuracy is ≥92%, reducing trial-and-error costs.
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Industrial Design Details
- Compact Body: 2300×1100mm footprint fits well in lighting factory workshops. The 650KG weight allows flexible relocation to different production lines.
- Low-Noise Design: The servo system is enclosed in a soundproof cover, with an operating noise ≤72dB (1m away), complying with ISO workshop environment standards.
- Fault Warning: Real-time monitoring of die temperature and servo motor load. When the bending die temperature exceeds 60°C, the cooling system automatically activates, reducing downtime risks.
From minimalist table lamps to luxurious chandeliers, from standard components to artistic customizations —— the 2D Wire Bending Machine, with servo-grade precision and CAD flexible design, transforms every iron wire into the cornerstone of lighting aesthetics. By adopting this solution now, lighting fixture skeleton production can bid farewell to the era of "manual trial and error," illuminating the dual possibilities of mass production efficiency and design freedom with intelligent forming technology.
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Foshan Jinchun is a technology-intensive industrial company specializing in the development of welding technology and equipment research and manufacturing, integrating scientific research, production and sales.
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