3D Rotary Head Forming Machine: High-Efficiency Intelligent Equipment for Fan Guard & Blower Production

The 3D Rotary Head Forming Machine is a precision forming equipment developed based on CNC technology and servo drive systems. Specifically designed for fan guard and blower production, it possesses 3D spatial curve forming capabilities, enabling high-precision bending, coiling, and shaping of metal wires in an integrated process. As a key equipment in the blower manufacturing industry chain, this machine addresses the issues of insufficient precision and low efficiency in traditional forming equipment for complex surface processing through intelligent control technology, driving the transformation of fan guard production from semi-automation to full intelligence.

Suitable for producing fan guard components in the ventilation equipment manufacturing industry, including axial fans, centrifugal fans, industrial exhaust fans, etc., covering subdivisions such as household appliances, industrial equipment, and environmental ventilation. It can process round, flat, and special-shaped wires made of carbon steel, stainless steel, aluminum alloy, etc., with a wire diameter range of 3–8mm, meeting customized production needs for protective nets, guide covers, safety guards, and other components of different fan models.

. Basic Production Efficiency
Standard production speed: 8–10 pieces/minute (tested with Φ300mm fan guard as the benchmark component)
Wire diameter processing range: 3mm (minimum)–8mm (maximum), supporting 0.1mm-level wire diameter parameter subdivision adjustment
Daily production capacity (24-hour continuous operation): 11,520–14,400 pieces, with a 20% capacity increase when equipped with a dual material rack automatic switching system
. Intelligent Production Management
Real-time HMI display: 9 core data items including current production, cumulative production, production rate, and equipment load rate
Automatic production control: Preset production thresholds (adjustable from 1–99,999 pieces), executing a three-level shutdown procedure of "decelerate–inspect–shutdown" upon reaching the target, with shutdown position accuracy of ±0.5mm

. Feeding System
Automatic feeding rack: Servo motor-driven adjustable tension control system with high-precision encoder (2000 lines/revolution), feeding accuracy ±0.05mm
Main machine spacing design: 2000–3000mm adjustable rail connection (2000mm standard), real-time monitoring of spacing deviation via laser rangefinder to ensure no wire stretching deformation
. Forming System
Rotary head mechanism: Seven-axis 联动 CNC rotary head (3 rotational axes + 4 linear axes), combining harmonic drive reducers (transmission accuracy ±15 arcseconds) and linear guides (ISO 2526-2 precision grade)
Mold change: Quick-release mold interface (change time <5 minutes), supporting memory storage of 32 sets of mold parameters

. Network Interconnection Architecture
Operating system: Customized industrial-grade Windows 10 IoT system, supporting OPC UA industrial communication protocol
Remote control: Access to factory MES system via 4G/5G or wired network, enabling real-time equipment status monitoring (dual-link real-time video + data), remote program upload/download, and fault diagnosis alarms
Security mechanism: AES-128 data encryption transmission, supporting two-factor authentication (account password + device fingerprint)
. Programming and Debugging System
Three programming modes:
Tabular programming: Visual parameter table (supporting Excel import/export) with 32 motion axis control parameters, reducing programming time by 60% compared to traditional G-code
Teaching programming: Manually drag the rotary head to target positions (recorded with 0.01mm-level precision), automatically generating motion trajectory programs
Axis coordinate programming: Direct input of axis coordinates (X/Y/Z axis resolution 0.001mm, rotational axis 0.01°), supporting polar/Cartesian coordinate switching
Real-time debugging functions: Handwheel pulse equivalent of 0.01mm/pulse, jog mode supporting 0.1mm/step fine-tuning, with synchronous modification of 12 motion parameters like speed and acceleration during debugging
. Precision Control Technology
Synchronous control: Full closed-loop control scheme calibrated by Renishaw XL-80 laser interferometer, each axis equipped with absolute encoders (24-bit resolution), achieving nanometer-level position compensation via digital servo drives (response frequency 500Hz)
Error correction: Built-in 9-point temperature compensation algorithm (temperature sensor accuracy ±0.5℃), real-time correction of thermal deformation effects on mechanical structures due to ambient temperature

. Adjustable Parameter Matrix
Motion parameters: Maximum speed per axis (adjustable 1–2000mm/s), gear ratio (1:1–1:100), motion direction (forward/reverse), acceleration/deceleration curves (S-shaped/linear)
Process parameters: Bending angle (0–360°), forming radius (1–200mm), springback compensation coefficient (0–100%)
Equipment parameters: Air pressure threshold (0.4–0.8MPa), lubrication cycle (1–24 hours), alarm thresholds (temperature/current/vibration parameters)
. Data Management Functions
Backup and recovery: Supports dual backup via USB/cloud, single backup time <30 seconds, storing 100 groups of historical parameters
Version management: Automatic recording of parameter modification logs (time/operator/modification content), supporting parameter version comparison and rollback

. Fully Automated Production Process
Fully automated process: Feeding–forming–cutting–unloading, with optional visual inspection modules enabling 100% online full inspection
Changeover time: <15 minutes for regular product switching, <5 minutes for mold-shared product switching
. Energy Consumption Optimization Design
Servo system energy saving: Uses permanent magnet synchronous servo motors (IE5+ efficiency grade), saving 35% energy compared to traditional asynchronous motors
Intelligent sleep mode: Automatically enters low-power mode (<50W) after 5 minutes of idling, waking up within 3 seconds upon receiving production commands

. Multi-Axis Linkage Precision
Positioning accuracy: ±0.01mm (linear axis), ±0.01° (rotational axis)
Repeat positioning accuracy: ±0.005mm (linear axis), ±0.005° (rotational axis)
Typical workpiece precision: Φ300mm guard roundness error ≤0.1mm, bending angle error ≤0.5°
. Process Control Technology
Adaptive tension control: Real-time monitoring of wire tension (accuracy ±1N), dynamically adjusting feeding speed and rotary head torque
Vibration suppression algorithm: Collects vibration data via acceleration sensors (sensitivity 100mV/g), controlling vibration amplitude within 0.1g using PID + feedforward control algorithms

. Operation Interface Design
15-inch capacitive touchscreen (1920×1080 resolution), supporting gesture zoom and custom function shortcuts
Multi-language interface: Real-time switching between Chinese/English/Japanese/Korean, automatic adaptation of parameter units (mm/inch/°/rad)
. Safety Protection System
Hardware protection: Fully enclosed safety light curtains (response time <10ms), emergency stop buttons (reset time <2 seconds), overload protection sensors
Software protection: Soft limits for motion axes (±10mm buffer zone), pre-program collision detection algorithm, abnormal power-off protection (data retention ≥72 hours)

The 3D Rotary Head Forming Machine redefines the technical standards for fan guard and blower production through its "high-speed production + high-precision control + high-intelligence" trinity design. The equipment not only achieves a leap from "manufacturing" to "intelligent manufacturing" but also provides flexible production best practices for discrete manufacturing enterprises through innovative functions like parametric programming and remote maintenance. With the deep integration of industrial internet and AI technologies, this equipment will continue to empower the ventilation equipment industry, driving production models toward greater efficiency, intelligence, and sustainability.