3D Wire Rotating Forming Machine: The Intelligent Core Equipment for Dumbbell Stand Production

In the field of dumbbell stand production, the structural stability and forming complexity of products directly determine their load-bearing capacity and usage safety. The 3D wire rotating forming machine, with its multi-dimensional motion control, precise wire feeding accuracy, and powerful power output, has become the core equipment for processing dumbbell stands from iron wire raw materials to finished products. This automated forming equipment specially designed for 3-8mm iron wires, with a total power of 10.7KW and a production speed of 6-8 pieces per minute, perfectly adapts to the complex three-dimensional structure processing needs of dumbbell stands, bringing an efficient, precise, and stable production solution to the industry.

The power configuration of the 3D wire rotating forming machine can be called an industry benchmark. Seven motor modules have clear divisions of labor, jointly supporting the entire process of dumbbell stand processing. The external torsion motor and internal torsion motor are each equipped with 1.5KW power, which can realize multi-angle torsion of iron wires in three-dimensional space, easily completing complex structures such as cross nodes and bending arcs of dumbbell stands; the platform lifting and overall lifting motors are each 1.0KW, ensuring precise displacement of the processing platform in the height direction to adapt to the forming needs of different specifications of stands.

The wire feeding motor is driven by 2.7KW power, and with 18 straightening wheels, it can stably convey 3-8mm iron wires at a maximum wire feeding speed of 40 meters per minute, while ensuring a wire feeding accuracy of 0.1±mm. This accuracy is crucial for dumbbell stands. If the distance between the load-bearing rods of the stand and the position deviation of the connection points exceed 0.5mm, it may cause the dumbbell to be placed unstable, and the accuracy control of this equipment avoids such risks from the source. The 2.0KW wire rotating motor and 1.0KW cutter motor are respectively responsible for the direction adjustment and cutting of the iron wire, ensuring that the length error of each section of wire is controlled within the minimum range.

The equipment is connected to 380V voltage, and the operating voltage is stable at 220V. The 20KVA capacitance ensures stable power supply when multiple motors start simultaneously, avoiding the impact of voltage fluctuations on processing accuracy. The combination of the 2000KG machine weight and Taiwan HIWIN screw guides further improves the stability of the equipment during operation. Even when processing 8mm thick iron wires, the machine amplitude can be controlled within 0.1mm.

The production of dumbbell stands has two core requirements for equipment: the forming ability of three-dimensional structures and the stability of continuous production. The 3D wire rotating forming machine performs outstandingly in both aspects. For the common "U-shaped load-bearing frame + cross reinforcement rod" structure of dumbbell stands, the equipment can complete complex actions such as three-dimensional crossing and multi-angle bending at one time through 360° rotation control of the external and internal torsion motors, combined with height adjustment of the platform lifting, without the need for secondary processing.

In terms of production efficiency, the speed of 6-8 pieces per minute seems conservative, but it is actually designed for the heavy structure of dumbbell stands. 3-8mm iron wires have strong rigidity, and sufficient pressure-holding time is required during bending to ensure stable forming. Compared with ordinary plane forming equipment, its efficiency has been increased by more than 3 times. Taking a standard dumbbell stand (with a load capacity of 50kg) as an example, traditional manual-assisted forming requires 3 people to cooperate, with a daily output of less than 500 pieces, while a single unit of this equipment can achieve a daily output of 800-1000 pieces, and the qualified rate of finished products has increased from 75% to 99%.

Wire feeding accuracy is another highlight. The control accuracy of 0.1±mm means that the length error of each section of iron wire does not exceed 1/5 of the diameter of a hair, ensuring that the symmetry and hole spacing of the dumbbell stand are completely consistent. This accuracy is particularly critical in the assembly process, which can reduce more than 90% of manual adjustment time and significantly improve downstream assembly efficiency.

Intelligent operation is one of the core competitiveness of the 3D wire rotating forming machine. The equipment is equipped with a Chinese/English bilingual operation interface, supporting operators with different language backgrounds to get started quickly. The number of 10,000 sets of supportable programs can cover the full range of product specifications from small household dumbbell stands to large commercial combined stands. Whether it is a single-bar type, multi-layer type, or foldable structure, the equipment can automatically call parameters as long as the program is written in advance.

The addition of Taiwan HIWIN screw guides increases the response speed of the equipment's motion control by 40%. Combined with the multi-stage straightening of 18 straightening wheels, even raw iron wires with large curvature can be adjusted to a straightness within 0.5mm/m. When it is necessary to switch product models, operators only need to input new parameters or call preset programs on the interface, and the equipment can complete the full parameter switching from wire feeding speed, torsion angle to cutter position within 3 minutes, greatly shortening the production change time.

The size design of the equipment is 3.45M1.85M1.45M, which takes into account the space layout needs of the production workshop. Although the weight of 2000KG seems heavy, the shock-proof foot pads at the bottom can effectively reduce the impact on the ground during operation, adapting to the ground bearing standards of most industrial plants.

For dumbbell stand manufacturers, the introduction of the 3D wire rotating forming machine is not only an update of equipment but also an upgrade of the production mode. In traditional production, the three-dimensional structure of dumbbell stands needs to be processed in multiple processes. Manual bending is prone to angle deviations, and the rejection rate is high due to inconsistent sizes during welding; ordinary forming equipment is limited by plane motion and cannot complete complex three-dimensional torsion. This 3D wire rotating forming machine has achieved three major breakthroughs through the combination of "multi-motor collaboration + high-precision control + intelligent programs":

First, integrated structural forming: Integrating processes such as bending, torsion, and cutting of dumbbell stands into a continuous process, avoiding precision loss caused by secondary processing, and increasing the load-bearing strength by more than 20%.

Second, significant cost reduction: A single equipment can replace 4-5 workers, saving more than 150,000 yuan in labor costs annually based on 8 hours of daily operation; a 99% qualified rate reduces raw material waste, saving about 3 tons of iron wire loss annually.

Third, flexible production capacity: The storage capacity of 10,000 sets of programs supports small-batch customized orders, enabling enterprises to quickly respond to market demands for special-shaped stands and multi-functional stands, and seize opportunities in homogeneous competition.

From professional fitness equipment in gyms to small fitness corners at home, the quality of dumbbell stands is directly related to the safety of users. With its powerful power configuration, precise forming control, and intelligent operation system, the 3D wire rotating forming machine has redefined the production standards of dumbbell stands, becoming the core driving force for promoting the industry towards high quality, high efficiency, and high flexibility.