Intelligent Loop Forming Machine: High-Efficiency Forming Solution for Aquaculture Circular Folding Cages

Core Positioning of the Equipment

A high-precision automated machine developed for the production of circular folding cages for fish, shrimp, and crab in aquaculture. It integrates full-process functions of wire feeding, straightening, cutting, and loop forming, achieving precise forming of ring skeletons for 3-8mm iron wires (round/flat/square). Through the collaborative control of servo drive and hydraulic system, it solves the pain points of low efficiency and poor precision in traditional manual loop forming, providing one-stop production solutions from wire to ring components for aquaculture cages (such as lobster folding cages and crab enclosure rings), adapting to the needs of large-scale farming and customized specifications.

Technical Parameters at a Glance

Three-Dimensional Technological Innovations and Aquaculture Adaptation Advantages

1. Dual-Drive Forming by Servo and Hydraulic System
   • Precise Control of Feeding Servo: 2.3KW Inovance servo paired with 3 sets of precision-polished feeding wheels enables high-speed feeding at 63m/min without slipping for 8mm thick wires, with feeding stability improved by 30% compared to traditional machinery, ensuring the perimeter tolerance of folding cage ring frames ≤±0.2mm to meet the precision requirements for cage assembly.
   • Corrosion-Resistant Design of Hydraulic System: 1.5KW oil pump drives a flow of 160-320ml/min, with hydraulic pipelines made of stainless steel + anti-corrosion coating to adapt to the humid environment of aquaculture workshops. The adjustable oil pressure of 0.3-0.6MPa matches the hardness difference of 3-8mm wires, maintaining stable mold pressure during loop forming of 8mm iron wires to avoid wire cracking.
2. Flatness and Structure Strengthening Technology
   • 80% Flatness Control: Through a 9-roller progressive straightening system (light pressure on the first 3 rollers + heavy pressure on the next 6 rollers), the straightness of 3mm thin wires reaches 0.05mm/m, and the internal stress of 8mm thick wires is eliminated. After loop forming, the warp height of ring components ≤1/2 of the wire diameter, ensuring no distortion when the folding cage is unfolded, facilitating fishing net sewing.
   • Closed-Loop Control of Circumferential Precision: The encoder reads the feeding length in real time, and the microcomputer automatically adjusts the loop forming diameter according to the preset perimeter. The roundness error of an 800mm diameter ring frame ≤0.5mm, meeting the space requirements for multi-layer nested stacking of lobster cages.
3. Flexible Production Data Management
   • Storage of 1,000 Process Libraries: Built-in standard specifications for fish, shrimp, and crab cages (such as crab cages with a diameter of 300mm and lobster cages with a diameter of 500mm), with historical parameters retrievable in 2 minutes and model changeover debugging time ≤8 minutes, adapting to the seasonal order needs of aquaculture for "multi-specification and small-batch" production.
   • Graphical Programming Interface: The touch screen supports direct input of parameters such as loop diameter and wire diameter, automatically generating loop forming programs without coding. Aquaculture equipment operators can master it within 1 hour, reducing technical thresholds.
     

Comprehensive Analysis of Production Processes

1. Wire Pretreatment Process
   • Three-Stage Straightening Process: 0.3MPa light pressure straightening for 3mm wires, and two-stage heavy pressure of 0.5MPa (initial adjustment) + 0.6MPa (fine adjustment) for 8mm wires, combined with online detection by a 12μm laser micrometer to ensure no scratches on the wire surface after straightening, adapting to the pretreatment requirements for anti-rust painting of aquaculture cages.
   • Oblique Blade Cutting Technology: 40m/min cutter cylinder drives a 15° oblique blade, with the cutting end surface roughness of 8mm iron wires Ra≤25μm and no burrs, avoiding damage to fishing net fabrics and reducing subsequent grinding processes.
2. Typical Forming Case (5mm Iron Wire Crab Cage Ring Frame)
   1. Feeding servo conveys 1570mm wire (circumference of φ500mm ring) → secondary straightening by 9-roller straightening system;
   2. Hydraulic motor drives mold rotation, and the outer die bends clockwise at a speed of 100 rotations/min, while the feeding servo feeds uniformly;
   3. After the encoder detects that the feeding length meets the standard, the cutter automatically cuts the wire to form a closed ring;
   4. Single cycle of 7.5 seconds, ring perimeter tolerance ±0.2mm, flatness 82%, meeting the tight fitting requirements for multi-layer folding of crab cages.
3. Quality Control System
   • Load-Bearing Simulation Test: 20kg static pressure test on 8mm iron wire rings (simulating heavy loads suspended by aquaculture cages), with no deformation at bends, ensuring reliable load-bearing of lobster cages at a water depth of 2 meters.
   • Salt Spray Corrosion Test: Formed rings undergo a 48-hour salt spray test (simulating a marine environment), with surface rust spot area ≤5%, complying with the weather resistance requirements for aquaculture equipment in coastal areas.

Aquaculture Application Scenarios and Benefits

1. Large-Scale Farming Scenario (Case of a Lobster Farming Enterprise)
   1. Equipment Configuration: 2 loop forming machines + automatic welding line
   2. Production Specification: 400mm diameter lobster folding cage ring frame (6mm iron wire)
   3. Capacity Data: Single machine daily output 4,800 pieces, 2 machines monthly output >280,000 pieces, meeting the cage replacement needs of 500 mu lobster ponds
   4. Cost Optimization: Labor cost reduced from ¥1.2/piece to ¥0.3/piece, annual cost savings of ¥900,000
   5. Quality Improvement: Ring perimeter error reduced from ±1.0mm to ±0.2mm, cage folding failure rate reduced from 12% to 1.5%
2. Customized Flexible Production (Case of a Crab Farming Cooperative)
   1. Rapid Model Change: Switch between 3mm (crab seedling cage) and 8mm (adult crab cage) wire molds in 5 minutes through 1,000 process libraries, supporting the rapid production of different 规格 cages during the farming cycle.
   2. High-Value-Added Processing: Customized oval cage rings for high-quality aquatic products, achieving gradient bending through PLC programming to set parameters, increasing product premium by 40% compared to standard rings, adapting to the needs of high-end crab farming.

Intelligent Control System and Industrial Design

1. Electrical System Configuration
   • Anti-Humidity Design: The control box is equipped with a moisture-proof heater, which still operates stably in aquaculture workshops with humidity ≥90%. The PLC program supports offline backup to prevent data loss.
   • Intelligent Response to Material Breakage: The code detector monitors wire feeding in real time, automatically shutting down and giving an audible and visual alarm within 0.5 seconds in case of material breakage or jamming, reducing wire waste (single equipment saves about 1.2 tons of wire loss annually).
2. Mechanical Structure Strengthening
   • Compact Waterproof Body: 1300×750mm footprint adapts to the humid environment of aquaculture workshops. Key components adopt IP54 protection level, and hydraulic system seals use corrosion-resistant fluororubber, with service life twice that of ordinary materials.
   • Low-Noise and Energy-Saving Design: Servo motors are equipped with soundproof covers, with operating noise ≤75dB (1m away), complying with the environmental protection requirements of aquaculture farms. The hydraulic system uses energy-saving oil pumps, reducing energy consumption by 15% compared to traditional loop forming machines.