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2D Frame Bending and Butt-Welding All-in-One Machine: The Core Engine of Intelligent Production in the Stove Accessories Industry
2025-04-21
In the field of stove accessory manufacturing, with the intensification of market competition and the continuous improvement of consumers' quality requirements for products, the limitations of traditional production equipment in terms of efficiency, precision, and flexibility have become increasingly prominent. As an intelligent device integrating advanced technology and innovative design, the 2D Frame Bending and Butt-Welding All-in-One Machine is redefining the production standards of stove accessories with its breakthrough performance, becoming the core engine for industry upgrading and transformation.
![2D Frame Bending and Butt-Welding All-in-One Machine: The Core Engine of Intelligent Production in the Stove Accessories Industry 1]()
I. Full-Dimensional Parameter Analysis of the Equipment
(1) Basic Performance Parameters
- Equipment Name : 2D Frame Bending and Butt-Welding All-in-One Machine
- Industry Positioning : Specialized in the stove accessory manufacturing industry, precisely adapting to the production needs of core accessories such as stove frames, support structures, and connecting components
- Capacity Benchmark : Stable output efficiency of 8-10 pieces per minute, which is more than 300% higher than traditional manual production lines, with a daily capacity of 12,000-15,000 workpieces
- Material Compatibility : Core adaptation to iron-based materials, compatible with low-carbon steel, stainless steel, and other iron alloy materials to meet the diverse requirements of stove accessories for strength and corrosion resistance
- Wire Diameter Processing Range : Wide-range wire diameter processing capability of 3-8mm, covering the wire processing needs from fine parts to heavy structural parts
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Wire Universality
: Breakthrough realization of full-type coverage of round wires (diameter 3-8mm), flat wires (cross-sectional size 3×5mm-8×12mm), and square wires (side length 3-8mm), regardless of wire material, and can accurately process both metal wires and special alloy materials
II. Deconstruction of the Core Technical System
(1) Microcomputer Intelligent Control System
- Control Center Architecture : Equipped with an industrial-grade PLC microcomputer control system, using modular programming design, supporting the RS-485 communication protocol, and seamlessly docking with the factory MES system to achieve real-time monitoring of production data and remote operation and maintenance
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Program Editing Logic
:
- Features a graphical programming interface, allowing operators to set parameters such as bending angle (precision ±0.5°), bending radius (resolution 0.1mm), and feeding length (error ±0.2mm) through visual drag-and-drop modules
- Built-in 300 groups of preset action libraries, including basic action units such as straight bending, arc bending, and multi-segment folding forming, which can generate complex spatial curved surface structures through combination
- Dynamic Response Mechanism : Adopts a servo motor drive system with a positioning accuracy of ±0.05mm and a response time of <20ms, enabling precise start-stop and trajectory correction during high-speed movement
(2) Full-Process Automated Execution System
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Intelligent Feeding Module
:
- Uses a dual-axis servo feeding mechanism equipped with a high-precision encoder (resolution 1μm) to achieve fixed-length conveying and tension control of wires
- Integrates an automatic centering device that real-time detects wire offset through a vision sensor and automatically adjusts the feeding track position to ensure feeding accuracy
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Precision Straightening and Cutting Unit
:
- Seven-roll straightening mechanism with an adjustable roll spacing range of 2-10mm, driven by a synchronous belt, straightening speed up to 15m/min, and straightness error <0.1mm/m
- Hydraulic cutting system with carbide blades, cutting surface roughness Ra<000000>le;1.6μm, and cutting length tolerance ±0.3mm
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Multi-Axis Linkage Bending and Forming System
:
- Adopts a three-axis linkage structure (X/Y/Z axes), with an X-axis stroke of 300mm, Y-axis stroke of 200mm, Z-axis stroke of 150mm, and positioning accuracy of ±0.02mm
- Equipped with a replaceable bending mold library, supporting quick mold change (mold change time <5min). The molds are precision-machined by CNC, with a surface hardness of HRC58-62 and a service life of <000000>ge;500,000 times
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Automatic Ejection and Sorting System
:
- Pneumatic ejection device with adjustable ejection speed (5-20m/min), equipped with an elastic buffer mechanism to avoid surface damage to workpieces
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Vision sorting module that real-time detects workpiece size and shape through an industrial camera (resolution 2000×1500 pixels), automatically rejects unqualified products, and has a sorting accuracy rate of <000000>ge;99.5%
III. Scenario-Based Application Advantages
(1) Customized Production of Complex Structural Parts
In the field of high-end stove accessories, it is often necessary to produce complex frame structures with multiple bending angles and special-shaped cross-sections. Through the free combination of 300 groups of action settings, the equipment can achieve arbitrary combinations of dozens of basic bending forms such as "L-shaped→U-shaped→ω-shaped→S-shaped", easily completing complex processes such as three-dimensional curved surface forming of oven door frames and multi-segment folding bending of gas stove brackets. For example, a stove support with 4 bending angles and 2 arc transitions customized by an enterprise required 3 devices and 4 processes to complete using traditional processes, but this equipment can form it in one clamping, increasing production efficiency by 50% and reducing the defect rate from 8% to 1.5%.
(2) Flexible Production of Multi-Variety and Small-Batch Products
In response to the rapid changes in market demand, the equipment supports the "one-click production mode switching" function. By calling preset process programs, it can complete mold replacement and parameter adjustment from round wire processing to flat wire processing within 10 minutes, achieving rapid switching of different product specifications. In an overseas order undertaken by a stove accessory manufacturer, which included 12 different wire types and 8 wire diameter specifications, the flexible production capability of this equipment shortened the order delivery cycle by 40% and increased the inventory turnover rate by 35%, effectively reducing the enterprise's production and operation costs.
(3) High Efficiency in Large-Scale Mass Production
In mass production scenarios, the equipment's stability and capacity advantages are particularly prominent. Take an enterprise with an annual output of 5 million stove frames as an example. After adopting this equipment, the daily capacity of a single production line increased from 3,000 pieces to 8,000 pieces, the number of operators decreased from 6 to 2, and labor costs were reduced by 66.7%. At the same time, the equipment's continuous operation capability (24-hour uninterrupted production) ensures rapid order delivery, and the enterprise's on-time delivery rate increased from 85% to 98%, significantly enhancing market competitiveness.
IV. Industry Value Innovation
(1) Quality Control Upgrade
Through the precise control of the microcomputer program and full-process automation, the equipment realizes closed-loop control of all processes from wire feeding to finished product forming. The high precision of straightening and cutting ensures the basic dimensional accuracy of workpieces, the high repeatability of multi-axis linkage bending ensures the consistency of batch products, and the vision inspection and sorting system eliminates the outflow of unqualified products from the source. According to third-party test data, the dimensional qualification rate of stove accessories produced by this equipment is <000000>ge;99.2%, and the surface defect rate is <0.3%, significantly improving the overall quality level of stove products.
(2) Production Mode Innovation
The intelligence and automation characteristics of the equipment have promoted the transformation of stove accessory production from "labor-intensive" to "technology-intensive". Operators do not need to have profound process experience and can complete the production of complex products through simple parameter setting, reducing dependence on skilled labor. At the same time, the deep integration of the equipment with the factory information system has laid the foundation for the realization of "digital workshops" and "smart factories". A pilot enterprise has improved production management efficiency by 30% and accelerated decision-making response speed by 40% through the introduction of this equipment and supporting MES system, initially building an intelligent production system.
(3) Green Manufacturing Practices
In terms of energy consumption control, the equipment uses a servo motor energy-saving drive system, reducing energy consumption by more than 40% compared with traditional hydraulic drive equipment. At the same time, automated production reduces manual intervention and raw material waste, increasing material utilization from 78% to 92%. In addition, the noise generated during equipment operation is <75dB, meeting environmental protection standards and helping enterprises achieve green production goals.
V. Future Development Prospects
With the deepening of Industry 4.0, the 2D Frame Bending and Butt-Welding All-in-One Machine will continue to upgrade towards intelligence, networking, and servitization. In the future, the equipment is expected to integrate AI algorithms to achieve autonomous optimization of process parameters and fault prediction; realize remote collaborative control of equipment through 5G technology to build cross-regional flexible production networks; and provide customers with personalized process solutions based on big data analysis to further enhance the equipment's added value and industry service capabilities.
At the critical moment of transformation and upgrading in the stove accessories industry, the 2D Frame Bending and Butt-Welding All-in-One Machine has become a must-have equipment for enterprises to enhance their core competitiveness with its leading technology, excellent performance, and broad development potential. It is not only a production device but also an important engine to promote the industry's development towards high-end and intelligent directions, leading the stove accessory manufacturing industry to a new development stage.
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Foshan Jinchun est une entreprise industrielle à forte intensité technologique spécialisée dans le développement de technologies de soudage et de recherche et de fabrication d'équipements, intégrant la recherche scientifique, la production et la vente.
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