In - depth Introduction to 2D Wire Bending Machine

(Ⅰ) Equipment Positioning and Industry Adaptation

(Ⅱ) Regional Production Advantages

(Ⅲ) Material and Wire Diameter Expansion

• Material Characteristics: Specialized technical research and development have been conducted for the physical properties of iron wire (such as hardness and ductility). The bending molds of the equipment are made of wear - resistant alloy materials, which can effectively cope with the stress loss during the bending process of iron wire and ensure the precision stability in long - term production.
• Wire Diameter Coverage: It can process iron wires with a wire diameter of 2 - 6mm. Through an intelligent adjustment system, it can easily achieve seamless switching production of iron wires with different diameters. Whether it is a slender and delicate craft fan skeleton (such as a hollow carved skeleton made of 2mm wire diameter) or a strong and durable industrial fan skeleton (such as a heavy - duty skeleton of 6mm wire diameter), it can be accurately formed.

(Ⅳ) Analysis of Production Capacity Data

• Basic Production Capacity: With a stable production speed of 10 - 15 pieces per minute, based on an 8 - hour working system, the daily production capacity can reach 4,800 - 7,200 skeletons, which is 8 - 10 times more efficient than traditional manual production.
• Elastic Production Capacity: By optimizing program parameters and the equipment's operation rhythm, the production capacity can be further increased by 10% - 15% in urgent production scenarios, helping enterprises flexibly respond to order fluctuations.
  

Ⅱ. Analysis of the Core Technical System

(Ⅰ) Microcomputer Intelligent Control System

1. Program Editing and Operation

• It adopts an industrial - grade PLC microcomputer control system, supporting both G - code programming and graphical interface programming modes. Operators can directly draw the bending graphics of the skeleton through the touch screen, and the system automatically generates bending programs, reducing the programming threshold.
• It has a program storage and calling function, which can store more than 500 groups of production programs for different specifications of products. It can switch production tasks with one key, significantly shortening the model change time, especially suitable for the flexible production needs of multiple varieties and small batches.

2. Dynamic Parameter Adjustment

• During the bending process, the system can real - time monitor the stress condition and bending angle of the iron wire, and automatically fine - tune the bending speed (adjustable from 0.1 to 5mm/s) and pressure (adjustable from 5 to 50KN) to ensure that skeletons of different wire diameters and shapes can achieve the ideal forming effect.
• It is equipped with a built - in fault diagnosis module, which can carry out real - time early warning and positioning for abnormal situations (such as program errors and sensor failures) during the program operation process, helping operators quickly troubleshoot faults and reduce downtime.

(Ⅱ) Full - process Automated Mechanical System

1. Intelligent Feeding Unit

• It adopts a ball screw feeding mechanism driven by a servo motor, with a feeding accuracy of ±0.1mm. The feeding speed can be automatically adjusted according to the production rhythm (adjustable from 10 to 100mm/s) to ensure synchronization and coordination with the bending action.
• It is equipped with an iron wire straightening device composed of multiple groups of straightening wheels, which can efficiently straighten iron wires with a bending degree ≤5°, and the straightness of the straightened iron wire is ≤0.5mm/m, providing high - quality raw materials for the subsequent bending process.

2. Precision Cutting Unit

• It adopts a pneumatic cutting method, and the cutting blade is made of hard alloy material, with a sharp edge and wear resistance. The cutting length can be arbitrarily set within the range of 50 - 500mm, and the cutting error is ≤±0.5mm.
• The cutting process is  (linkage - controlled) with the feeding and bending processes, realizing the seamless connection of "feeding - straightening - cutting - bending", improving production efficiency and avoiding iron wire waste.

3. Multifunctional Bending Unit

• The bending mechanism adopts a five - axis linkage design, which can realize the linear motion of the X, Y, Z axes and the rotational motion of the A, B axes, and can complete the bending of complex shapes such as right angles, arc angles, and multi - segment polylines.
• The bending angle range is 0 - 180°, and the angle accuracy can reach ±1°. By replacing bending molds of different specifications (10 sets of common molds are provided as standard), the production conversion of different shapes of skeletons can be quickly realized.

4. Automatic Unloading and Sorting Unit

• The unloading mechanism is designed with a pneumatic push rod, which can quickly push the product out of the working area after the skeleton is formed, with an unloading speed ≤2 seconds per piece.
• It is equipped with a visual inspection and sorting system, which can carry out online inspection of the size, shape, surface quality, etc. of the skeleton, automatically remove unqualified products, and collect qualified products by specification, improving the product qualification rate and production management efficiency.
  

Ⅲ. Core Competitive Advantages of the Equipment

(Ⅰ) Benchmark of High - Precision Manufacturing

• Through the perfect cooperation between the microcomputer control system and the precision mechanical structure, the high - precision control of the key dimensions of the fan skeleton (such as bending radius, skeleton length, angle deviation, etc.) is realized. Verified by a third - party testing agency, the dimensional accuracy error is ≤±0.3mm, and the angle accuracy error is ≤±1.5°, fully meeting the strict requirements of high - end fan brands for product quality.
• Case: After a well - known craft fan production enterprise introduced the 2D wire bending machine, the product defect rate dropped from the original 15% to below 3%, the customer complaint rate decreased by 80%, and the product premium ability was significantly improved.

(Ⅱ) Model of Flexible Production

• With its strong program editing ability and fast mold - changing technology, the equipment can complete the production switch from one specification of skeleton to another within 10 minutes, truly realizing "one machine with multiple functions".
• Application Scenarios: It can not only meet the needs of traditional fan factories for mass production of standard specification skeletons but also provide small - batch and high - value - added customized skeleton production services for cultural and creative studios and personalized customization enterprises, helping enterprises quickly respond to the diverse needs of the market.

(Ⅲ) Ergonomic Design

• The operation interface adopts a 10.1 - inch color touch screen, with a simple and intuitive interface, and the operation process conforms to the principles of ergonomics. Operators can independently complete production operations without long - term training.
• The overall layout of the equipment is reasonable, and the positions of each functional unit are convenient for operators to carry out daily maintenance and repair. It is equipped with safety protection devices (such as emergency stop buttons and safety light curtains) to ensure the personal safety of operators.

(Ⅳ) Energy - saving and Environmental Protection Characteristics

• It adopts a servo motor drive system, which reduces energy consumption by more than 30% compared with traditional hydraulic drive equipment. In the standby state, the equipment power is ≤50W, in line with national energy - saving standards.
• There is no oil pollution or waste gas emission during the production process, and the noise is ≤75dB, meeting environmental protection requirements and creating a green production environment for enterprises.

Ⅳ. Expansion of Diverse Application Scenarios

(Ⅰ) Traditional Fan Field

• Folding Fan Skeleton: It can produce folding fan skeletons of different sizes, such as 9 - inch, 10 - inch, and 12 - inch. Through precise bending, the arc requirements of the fan bones are realized, ensuring smooth opening and closing of the fan and beautiful appearance.
• Round Fan Skeleton: According to the characteristics of the circular or elliptical skeleton of the round fan, the equipment can complete multi - segment arc bending to create a round fan skeleton with smooth lines and a stable structure, suitable for different fan surface materials such as silk and cloth.

(Ⅱ) Craft Fan and Gift Fan Field

• Artistic Modeling Skeleton: It supports the bending design of complex shapes, such as the skeleton models of patterns like flowers and birds, landscapes, and figures, providing unlimited possibilities for the artistic creation of craft fans. A craft fan studio used the 2D wire bending machine to produce hollow carved skeletons, which were successfully selected into the national intangible cultural heritage cultural and creative product list.
• Gift Customization Skeleton: It can bend personalized logos (such as enterprise LOGOs and blessing words) on the skeleton according to customer needs, which is used for the production of gift fans such as advertising fans and commemorative fans, enhancing the sense of exclusivity and commemorative value of the gifts.

(Ⅲ) Industrial and Special Purpose Fields

• Industrial Cooling Fan Skeleton: Aiming at the high requirements of industrial cooling fans for the strength and stability of the skeleton, the equipment can produce skeletons with large wire diameters (such as 6mm) and large specifications to ensure the safety and reliability of the cooling fan during high - speed operation.
• Skeleton of Fans for Special Environments: It can produce skeletons of special materials that are corrosion - resistant and high - temperature - resistant (requiring matching with corresponding material iron wires), suitable for fans used in special environments such as chemical industry and high temperature, expanding the application scenarios of fans.
  

Ⅴ. After - sales Service and Cooperation Guarantee

(Ⅰ) Comprehensive Training Support

• Provide customers with operation training and programming training, including equipment operation, program editing, daily maintenance, etc., to ensure that customer operators can master the equipment use skills proficiently.
• The training methods are flexible and diverse, and can adopt on - site training, remote video training, etc., to meet the needs of different customers.
• Regularly  (visit) customers to understand the equipment usage situation, provide preventive maintenance suggestions, help customers extend the equipment service life, and reduce operating costs.

(Ⅱ) Long - term Technical Cooperation

• Provide customers with program upgrade services. According to the industry technical development and customer actual needs, continuously optimize the equipment control system program to improve the equipment performance and functions.
• Establish a technical cooperation and research and development mechanism with customers to jointly develop new fan skeleton products and production processes, helping customers maintain a leading position in market competition.