In - depth Analysis of 2D Frame Bending and Butt - Welding All - in - One Machine

I. Comprehensive View of Equipment Basic Information

(1) Professional Positioning and Industry Adaptation

(2) Power Supply and Safety Standards

Power Supply Specifications : It adopts a three - phase 380V industrial - grade power supply configuration with an independent grounding wire design, complying with international electrical safety standards. Equipped with dual safety mechanisms of overload protection and leakage monitoring, it can automatically cut off the power supply within 0.1 seconds when the current is abnormal or the equipment leaks. This ensures the operation safety of production line personnel and the stability of equipment operation. It can be adapted to the power environments of various industrial plants and guarantee 24 - hour continuous production without power outages.

II. Multidimensional Analysis of Core Performance Parameters

(1) Efficiency Matrix: Multi - Scenario Capacity Optimization

(2) Material and Wire Diameter Adaptation System

• Product Materials : It is deeply adapted to iron - based materials such as Q235 carbon steel and stainless steel (customizable). Through the material stress analysis algorithm, it can automatically optimize the bending angle and welding parameters to avoid the risk of material cracking, especially suitable for the dual needs of bathroom baskets for corrosion resistance and bearing strength.
• Wire Diameter Processing Range : It covers the full range of 3 - 8mm. Equipped with an intelligent wire diameter recognition sensor, it can automatically detect the diameter of the iron wire and match the straightening pressure parameters. When switching materials with different wire diameters, the system automatically calls the preset process parameters, and the model change time is shortened to less than 5 minutes, reducing manual debugging errors.

(3) Technical Parameters of Core Components

1. Straightening System: The Core Engine of Precision Straightening
   • Straightening Wheel Configuration : A 28 - group high - precision straightening wheel array is used, made of national standard Cr12 die steel substrate, and the surface is strengthened by SKD11/51 powder metallurgy process. The Rockwell hardness reaches 62°, and the wear resistance is 40% higher than that of ordinary die steel.
   • Straightening Precision : The "three - stage straightening process" is adopted - pre - straightening (eliminating large - angle bending), precision straightening (tolerance ±0.1mm), and stress relief straightening (reducing internal material stress), ensuring that the straightness of the iron wire is <000000>le;0.3mm/m, laying a high - precision foundation for subsequent bending and forming.
2. Wire Feeding System: The Power Center of Stable Transmission
   • Wire Feeding Wheel Structure : A 3 - group dual - drive wire feeding wheel set is adopted, with a dual - mode design of "gear meshing + friction drive". Gear drive ensures the stable wire feeding torque of thick wire diameters (6 - 8mm), and friction drive guarantees the wire feeding precision of thin wire diameters (3 - 5mm) to avoid slipping and damaging the surface of the wire.
   • Rawatan Permukaan : After fine polishing, the surface roughness of the wire feeding wheel is Ra<000000>le;0.8μm, and with a heat treatment hardness of 58°, it realizes "zero scratch" wire feeding, which is especially suitable for the aesthetic requirements of exposed wires in bathroom baskets.
3. Control System: The Brain Center of Intelligent Production
   • Control Core : It is equipped with an industrial - grade microcomputer controller and adopts a PLC + touch screen human - machine interaction interface, supporting the storage of 200 groups of process parameters. Operators can real - time monitor the production progress and equipment status (such as mold temperature, motor speed, etc.) through the visual interface, and can remotely access the factory MES system to realize real - time synchronization of production data.
   • Servo Drive : High - precision servo motors of Yaqi brand are used, with a positioning precision of ±0.02mm and a response speed of 0.01 seconds. In the bending action, through the precise cooperation of the servo motor and the ball screw, the bending angle control of 0.1° level is realized, and the arc bending with any radius of R3 - R50mm can be completed to meet the forming needs of complex structures such as the arc frame and special - shaped hooks of bathroom baskets.
4. Action Setting System: The Soul of Flexible Production
   • Programmable Action Library : It has a built - in 300 basic action units, covering functional modules such as straight bending, arc bending, multi - angle continuous bending, and automatic butt welding. Through the "action combination editor", engineers can quickly design new machine types like building blocks. For example:
     • For bathroom triangular baskets: call the combination of "90° bending + arc transition + three - point butt welding" to form the basket frame at one time;
     • For laundry basket handles: through "continuous wave - shaped bending + precise positioning welding", the consistency error of the handle arc is <000000>le;1mm.
   • Quick Mold Change System : It adopts a pneumatic chuck - type mold installation structure. Changing the bending mold only takes 3 minutes. With the automatic tool setting function, the manual tool setting time is reduced, and the flexible switching of the "multi - variety, small - batch" production mode is truly realized.
     

III. In - depth Decoding of Equipment Competitive Advantages

(1) Precision Revolution: Micron - Level Manufacturing Standards

• Bending Precision : Through the coordinated control of the servo system and high - precision molds, the bending angle error is <000000>le;±0.5°, and the side length dimension tolerance is ±0.3mm, meeting the strict assembly requirements of bathroom baskets with bathroom cabinets and wall mounting holes and reducing after - sales installation disputes.
• Welding Quality : The medium - frequency inverter welding technology is adopted, and the welding time control precision reaches 1ms. The solder joint diameter is adjustable from φ2.5 to 4mm, and the welding strength is <000000>ge;80MPa, far exceeding the industry standard of bathroom baskets (<000000>ge;50MPa), ensuring that the basket can bear a weight of <000000>ge;20kg without deformation or welding breakage.

(2) Efficiency Leap: Full - Process Automation Empowerment

• Unmanned Production Unit : The whole process from iron wire uncoiling, straightening, cutting, bending, butt welding to finished product blanking does not require manual intervention. With an automatic feeding rack (optional), it can realize 8 hours of unattended production, significantly reducing labor costs (3 - 5 operators can be saved in a single shift production).
• Rapid Model Change Capability : Through the intelligent process parameter calling + quick mold change system, it only takes 15 minutes to switch from producing square baskets to round baskets, saving 70% of the model change time compared with traditional equipment, especially suitable for undertaking the multi - style order needs of bathroom brand owners.

(3) Cost Optimization: Improvement of Full Life Cycle Value

• Energy Consumption Control : The servo system adopts an energy - saving design, with a standby power of <000000>le;5kW and a normal production power of <000000>le;25kW, which is more than 30% energy - saving compared with similar equipment. Calculated according to 16 hours of daily operation, the annual electricity cost can be saved by about 20,000 yuan (calculated at 0.8 yuan/kWh).
• Maintenance Cost : Key components (such as straightening wheels and wire feeding wheels) adopt a modular design, and the equipment does not need to be disassembled as a whole when replacing, shortening the maintenance time by 50%. It is standard - equipped with a remote fault diagnosis function, and engineers can real - time analyze the equipment operation data through the cloud system, giving advance warnings of potential faults and reducing unplanned downtime losses.

(4) Process Innovation: One - Step Forming of Complex Structures

• Multi - Axis Linkage Technology : The equipment is equipped with a 3 - axis linkage bending mechanism, which can complete the bending actions in the X/Y/Z three directions at the same time, easily realizing the forming of three - dimensional structures (such as the bottom reinforcing ribs and side hooks of the basket), reducing the secondary processing cost of multi - process splicing in the traditional process.
• Intelligent Butt Welding System : Equipped with a visual sensor, it can automatically identify the position of the bent workpiece, and drive the welding torch to achieve precise positioning welding through the servo motor. For special - shaped parts, the welding path can be preset through offline programming software to ensure that the solder joint position error is <000000>le;0.5mm, improving the welding aesthetics and consistency.
  

IV. Typical Application Scenarios and Value Presentation

(1) Full Product Category Coverage of Bathroom Baskets

(2) Customer Case: The Capacity Upgrade Record of a Bathroom Enterprise

• Customer Pain Points : The original equipment could only produce simple square baskets and could not meet the needs of brand owners for arc baskets and multi - layer combined baskets; the manual machine adjustment time was long, and the model change efficiency was low, resulting in losses in small orders.
• Penyelesaian : Introduce the 2D frame bending and butt - welding all - in - one machine, configure the arc bending mold and intelligent butt - welding system, and develop 12 new types of basket products; realize the rapid switching of different products through the process parameter storage function.
• Application Effect : The monthly production capacity increased from 50,000 pieces to 120,000 pieces, and the profit margin of new products reached 45%; the model change time was shortened from 2 hours to 15 minutes, and the delivery cycle of small orders was compressed from 7 days to 3 days, successfully seizing the high - end bathroom market.

V. After - Sales Service and Technical Support

(1) Full Cycle Service System

• Installation and Debugging : Provide on - site installation services. Engineers will complete equipment debugging, parameter setting and operator training on site to ensure that the equipment can be put into production upon delivery.
• Warranty Service : The whole machine is guaranteed for 2 years, and the core components (servo motor, microcomputer controller) are guaranteed for 5 years. Free software upgrade services are provided for life.
• Emergency Response : 7×24 - hour after - sales hotline, remote fault diagnosis within 4 hours, on - site service within 24 hours (for customers within the province), and major faults solved within 48 hours.

(2) Technical Training and Process Support

• Operation Training : Provide three - level operation training courses (primary, intermediate and advanced), and let operators quickly master the design skills of complex machine types through the simulation system.
• Process R & D : Cooperate with university research teams to provide customers with customized services such as new material processing technology development and new product proofing, helping customers maintain product innovation competitiveness.