In - depth Analysis of 3D Wire Forming Machine

I. Tracing the Basic Information of the Equipment

II. Panoramic View of Core Performance Parameters

(A) Analysis of Dynamic Production Capacity

• Intelligent Adjustment Range of Production Speed: With a benchmark production capacity of 6 - 8 pieces per minute, it can be dynamically fine - tuned according to the complexity of the wire and the requirements for processing precision. When dealing with simple straight brackets, the production capacity can reach the upper limit of 8 pieces per minute. In the face of complex structures such as multi - layer arc - shaped frames, the system automatically reduces the speed to 6 pieces per minute to ensure that the forming precision error of each workpiece is controlled within ±0.1mm, achieving a dynamic balance between efficiency and quality.

(B) Expansion of Material Processing Range

• Compatibility Matrix of Iron Materials:
  • Mild Steel (Q235): It is suitable for basic components such as bowl racks and layer racks with moderate strength requirements. After forming, the surface roughness Ra≤12.5μm.
  • Stainless Steel (such as 304): It can process exposed components with high corrosion resistance requirements, such as cabinet door hinges and handles. Through exclusive mold technology, it avoids ferrite pollution and ensures the corrosion resistance of stainless steel materials.
• Stepped Processing Capacity of Wire Diameter:
  • Fine Wire Processing Module (3 - 5mm): Equipped with wire feeding wheels with a fine - tuning accuracy of 0.01mm and using progressive bending molds, it can form acute structures with a radius ≥2mm, suitable for the dense chopstick rack grids inside disinfection cupboards.
  • Thick Wire Processing Module (6 - 8mm): Equipped with a hydraulic drive forming mechanism, the maximum bending force reaches 50kN, and it can handle the forming of iron pipes with a wall thickness ≥1.5mm, meeting the high - strength processing requirements of the base brackets of heavy - duty disinfection cupboards.

(C) Engineering Design of Precision Straightening System

• Topological Structure of 18 - wheel Straightening Mechanism: Adopting a layout of "9 groups of upper and lower staggered straightening wheel sets", the first 6 wheels are rough adjustment wheels (diameter 50mm, surface hardened to HRC60) for eliminating the original curvature of the wire. The middle 6 wheels are fine adjustment wheels (diameter 30mm, hard - chrome plated) to achieve a straightness of ≤0.05mm/m with high precision. The last 6 wheels are constant - temperature shaping wheels (with a built - in temperature control system to maintain 50℃±5℃), which eliminate the internal stress of the wire through aging treatment to ensure no springback deformation in the subsequent forming process.
  

III. In - depth Deconstruction of Intelligent Control System

(A) Innovation of Human - Machine Interaction Interface

• Technical Parameters of the Control Screen:
  • 15 - inch industrial - grade capacitive touch screen with a resolution of 1920×1080, supporting operation with gloves.
  • Multi - language switching function (Chinese/English/Japanese/Korean) to adapt to global production scenarios.
  • Real - time data dashboard: dynamically displays more than 20 core parameters such as wire feeding speed (0.1 - 5m/s), bending angle (0 - 180°), and mold temperature, with automatic red warning for abnormal data.

(B) Architecture of Special CNC Wire Forming System

• Three Technical Barriers of the Control System:
  • Trajectory Planning Algorithm: Based on the D - H parameter method for three - dimensional forming trajectory calculation model, it can automatically convert CAD design drawings into G codes and support the import of mainstream 3D formats such as STEP and IGES, realizing an integrated process of "design - programming - processing" and improving programming efficiency by 70%.
  • Servo Drive Technology: Using Panasonic MINAS A6 series servo motors with a positioning accuracy of ±0.005mm and a response speed of 0.1ms. Combined with a 2000 - line incremental encoder, it realizes nanometer - level interpolation control during multi - axis linkage and can process spiral structures with a curvature radius ≥1mm.
  • Process Database: It has a built - in database of more than 500 groups of processing parameters exclusive to the disinfection cupboard industry, covering forming solutions for different wire diameters, materials, and structures. New employees can quickly call up parameters through the "parameter matching wizard", reducing the debugging time to 1/3 of that of traditional equipment.
    

IV. Construction of Full - Scene Application Ecology

(A) Full Lifecycle Coverage of Disinfection Cupboard Components

• Pre - treatment Link: It is seamlessly connected with automatic leveling machines and rust removal cleaning lines to build an integrated production line of "straightening - cleaning - forming", reducing manual handling losses.
• Processing Scenarios of Core Components:
  • Bowl Racks: It can form wavy bowl rack support ribs (bending angle 120°±2°) and circular bowl rack borders (diameter accuracy ±0.3mm), adapting to the internal space design of disinfection cupboards with different volumes of 80 - 120L.
  • Intelligent Components: It processes UV lamp brackets (with 3 处 90° bends + 2 处 arc transitions) and thermostat mounting brackets (multi - hole positioning structure), meeting the needs of intelligent disinfection cupboards for precision installation components.
• Post - treatment Integration: It can be connected with automatic welding robots and surface spraying lines to achieve "dark - lamp" full - process production from wire to finished components.

(B) Cross - industry Expansion Potential

• Small Home Appliance Field: It is compatible with the processing of metal wire racks for kitchen small appliances (such as ovens and microwave ovens). By changing the mold, it can quickly switch to different product production lines.
• Medical Equipment: In the scenario of medical disinfection cupboards, it can process stainless steel instrument tray brackets, meeting the strict requirements of the ISO 13485 medical device quality management system for the cleanliness and corrosion resistance of components.

V. Construction of Value Creation System

(A) Cost Optimization Model

• Labor Cost: Using an intelligent operating system, one person can monitor 3 - 5 devices at the same time, saving 50% of the labor force compared with traditional equipment.
• Energy Consumption Management: In the energy - saving mode of the servo motor, the standby power ≤50W, and the production power consumption is 40% lower than that of hydraulic equipment, saving about 30,000 yuan in electricity costs per device per year (calculated based on 16 hours of operation per day).
• Mold Wear and Tear: Using Swedish ASSAB 88 mold steel and with the anti - collision warning function of the CNC system, the mold life is extended to more than 800,000 times, reducing the mold replacement cost by 30%.

(B) Quality Control System

• Integration of First Article Inspection: With a built - in laser vision detection module, it can complete full - size scanning within 5 seconds after the first article is processed, automatically generate a detection report, and the early warning response time for unqualified products ≤10 seconds.
• Process Quality Traceability: The system automatically records the processing parameters of each workpiece (such as wire feeding length, bending angle, mold number, etc.) to form a traceable quality file, meeting the requirements of the ISO 9001 quality management system.
  

VII. Value Proposition of After - sales Service

• Ultra - fast Response Mechanism: It provides 7×24 - hour remote diagnosis services. Through the OPC UA protocol, it can real - time obtain equipment operation data, with a fault early warning accuracy rate of more than 95%, and the average on - site maintenance time ≤4 hours (within the urban area).
• Process Upgrade Service: It provides 2 free industry new process parameter upgrades every year to help customers keep up with the design trends of lightweight and intelligent disinfection cupboards (such as new folding bowl rack forming processes).
• Green Circulation Solution: It supports the transformation and upgrading of old equipment. By replacing the control system and key components, the processing precision of traditional forming machines can be improved to ±0.2mm, extending the equipment service life by 3 - 5 years.