2D Wire Bending Machine + Punching: An Intelligent Solution for Full-Process Conveyor Mesh Belt Production

In the field of conveyor mesh belt manufacturing, efficient forming equipment is the core element to ensure product quality and production efficiency. Aiming at the special process requirements of iron conveyor mesh belts, the 2D wire bending machine + punching all-in-one machine has become a key equipment for realizing full-process automated production in the industry, relying on its integrated "wire bending-punching" design, high-precision processing capability, and intelligent control system. This article deeply analyzes this production tool customized for conveyor mesh belts from the dimensions of equipment technical architecture, core functional advantages, and industry application value.

The equipment adopts a three-phase four-wire 380V industrial power configuration to ensure stable operation in complex workshop environments. For the 2-6mm iron wires commonly used in conveyor mesh belts, a multi-level straightening and feeding system is specially designed: 28 groups of high-precision straightening wheels (45# steel quenched, hardness HRC55+) can eliminate the bending stress of raw iron wires, and 3 groups of Cr12 finely ground feeding wheels (hardness HRC58) cooperate with the servo drive system to achieve a wire feeding precision of ±0.2mm, laying a dimensional foundation for subsequent wire bending and punching processes.

In terms of power configuration, the equipment adopts a 4-axis servo drive scheme (total power 5.5kW): the 2.3kW wire feeding servo motor ensures uniform wire feeding, the 1.5kW bending servo motor supports high-speed bending at 150 times/minute, the 1.0kW punching servo motor can output a torque of 90N·m, and with a 40kW high-frequency welding transformer (optional), it forms a dynamic matrix combining rigidity and flexibility.

The mesh structure of conveyor mesh belts (such as diamond and rectangular meshes) has strict requirements for the precision of bending angles and arcs. The 2D wire bending module equipped with the equipment uses SKD11 precision molds (hardness HRC62), supporting arbitrary angle bending from 0-180°, with a bending precision of ±0.5mm. Through the cooperation of a 360° rotating worktable and a multi-directional moving mold base, it can achieve composite trajectory processing of "straight line-arc-polyline", meeting the forming needs of different parts such as the edge reinforcement section and load-bearing support section of the conveyor mesh belt.

The system has a built-in function of storing 4,000 groups of processing data, and a single group of programs can preset 300 action combinations, supporting one-click switching between the production of different specifications such as flat mesh, dense mesh, and heavy-duty mesh belts. Actual test data shows that for 90 ° right angle bending of 6mm iron wire, the equipment can maintain a stable processing frequency of 8-10 times per minute, which is 40% more efficient than traditional single machine bending.

The punching process directly affects the assembly precision and connection strength of mesh belt components. The servo-driven punching unit equipped with the equipment adopts a split mold design: the upper mold is made of Cr12MoV material (hardness HRC60), and the lower mold is inlaid with a cemented carbide bushing, which can process holes with a diameter of Φ3-Φ12mm (supporting customized special-shaped holes), and the punching position precision is ±0.3mm. The unique three-stage control algorithm of "preload positioning-fast punching-unloading reset" ensures that under the production speed of 8-10 pieces/minute, the punching burrs ≤0.1mm, avoiding the mesh belt operation jamming problem caused by burrs.

For the commonly used 20-100mm hole pitch design of conveyor mesh belts, the system supports various hole layouts such as linear arrays and matrix arrays, and can directly import CAD drawings through the touch screen interface to generate punching paths, significantly reducing programming difficulty. Tests show that during continuous punching operations on 4mm iron wires, the mold life can reach more than 500,000 times, and the maintenance cost is reduced by 60% compared with traditional punch presses.

In the traditional production mode, manual transfer of semi-finished products is required for separate processing of wire bending and punching by different equipment, resulting in cumulative positioning errors. This equipment realizes the forming processing of mesh belt unit parts at a single station through the full-process automation of "wire feeding-straightening-wire bending-punching", reducing the turnover time of two processes, and the production efficiency is increased by 35% compared with the traditional production line. Taking a 600mm wide conveyor mesh belt as an example, the daily production capacity of a single equipment can reach 1,200-1,500 meters, meeting the fast delivery needs of medium batch orders.

The smooth operation of the conveyor mesh belt depends on the consistency of the mesh: bending angle deviation will cause the mesh belt to run off track, and punching position error will affect the chain meshing precision. The equipment realizes closed-loop control of the two processes: the encoder position data is collected in real time during wire bending to correct the angle, and the mold reference is calibrated through the visual positioning system before punching, ensuring that the bending angle fluctuation of the same batch of products is ≤±0.3°, and the punching position deviation is ≤±0.2mm, fully meeting the strict requirements of high-end fields such as food processing and logistics conveying for mesh belt precision.

Facing the diversified specifications of conveyor mesh belts (wire diameter 2-6mm, changeable mesh shapes, different load-bearing grades), the equipment realizes flexible production through the following designs: ① Modular mold design, which can complete the replacement of wire bending dies and punching molds within 5 minutes; ② Automatic parameter matching algorithm of the servo system, which automatically adjusts the bending pressure and punching stroke after inputting the wire diameter parameters; ③ Chinese-English bilingual control system (supporting remote program download), which is convenient for the deployment of multinational enterprises in multiple factories. The practical application of a logistics equipment manufacturer shows that the equipment can be compatible with the production of more than 80% of conventional mesh belt models, and the model change time is shortened by 70% compared with traditional equipment.

With the development of conveyor mesh belts towards lightweight (such as 2mm thin wires for food-grade mesh belts), high-strength (6mm wire diameter load-bearing mesh belts), and multi-functionality (special treatments such as high temperature resistance and corrosion resistance), the equipment reflects technical forward-looking in the following aspects: ① Wire compatibility: In addition to iron wires, interfaces for stainless steel and galvanized wire processing are reserved, and non-ferrous metal processing can be expanded through mold material upgrades; ② Intelligent upgrade: Standard configuration of PLC + 32-bit high-performance processor, supporting data interaction with the MES system to realize real-time monitoring of production data; ③ Energy-saving design: The servo system uses energy feedback technology, saving more than 40% of electricity compared with traditional hydraulic equipment.

The 2D wire bending machine + punching all-in-one machine solves the problems of precision control and efficiency improvement in conveyor mesh belt production through process integration innovation and intelligent control technology, and has become a key hub equipment connecting raw materials and finished products. Its characteristics of "high precision, high flexibility, and high integration" not only bring direct production capacity improvement and cost optimization to enterprises but also promote the conveyor mesh belt industry to move towards automated and intelligent production. In the wave of Industry 4.0, such professional and forward-looking equipment is becoming the core driving force for the transformation and upgrading of traditional manufacturing industries.