What is a busbar punching, cutting and bending machine?
The busbar punching, cutting and bending machine is a highly automated processing equipment that integrates punching, cutting and bending functions. It is mainly composed of a hydraulic electric pump with a solenoid valve, a punching machine, a cutting machine, a bending machine, a workbench and a conversion switch. It is suitable for large workshops, power transmission and distribution site construction, and electrical appliance manufacturers such as distribution cabinets and switch cabinets. This equipment can efficiently process copper and aluminum busbars of different specifications. Users only need to operate in the corresponding processing unit to achieve a variety of processing such as cutting, punching and bending of the busbar, which effectively improves the processing efficiency and safety. It is an indispensable and important equipment in the electrical complete set manufacturing industry.
What are the functions?
The busbar punching, cutting and bending machine has powerful functions: punching, cutting and bending. The multi-functions are integrated in one busbar machine equipment, which can process the busbar quickly, efficiently and automatically. Its punching unit can accurately punch out holes of various shapes such as round holes and waist-shaped holes on the busbar, playing the role of a busbar punching machine; the cutting unit can accurately cut the busbar into the required length, playing the role of a busbar cutting machine; the bending unit is more flexible and diverse, and can complete various bending operations such as flat bending, vertical bending, embossing, flattening, twisting, etc., playing the role of a busbar bending machine. These functions enable the equipment to widely meet the diverse needs of high and low voltage switchgear, substations, bus ducts, bridges and other electrical complete set manufacturing industries for busbar processing, greatly improving production efficiency and processing quality, reducing labor costs, and providing strong support for the manufacture of electrical equipment.
Processing object: copper busbar and aluminum busbar
The main processing object of the busbar punching, cutting and bending machine is the metal conductor used to transmit and distribute large currents in the power system. Among them, copper busbars and aluminum busbars are common processing objects. Copper busbars are made of copper, and the cross-section is mostly rectangular or chamfered rectangular. They play a key role in transmitting current and connecting electrical equipment in the circuit. Aluminum busbars also play an important role in current transmission in some specific scenarios due to the characteristics of aluminum. These metal conductors are widely used in electrical equipment, especially complete sets of power distribution equipment. The equipment provides a solid guarantee for the stable operation of the power system through their precise processing.
Technical parameters and performance
The technical parameters of busbar punching, cutting and bending machines are an important reflection of their performance. In terms of processing accuracy, the punching accuracy can generally reach ±0.2mm, the cutting accuracy is ±0.2mm, and the bending angle accuracy is within ±0.3°, which can ensure the accuracy of busbar processing and meet the stringent requirements of electrical equipment for busbar connection and installation. In terms of processing efficiency, the punching speed is about 30 times/minute, the cutting speed can reach up to 30 meters/minute, and the bending speed is also relatively fast, which can greatly improve production efficiency and shorten production cycle. In terms of maximum processing size, different models of equipment are different, but they can usually meet the processing needs of copper and aluminum busbars of common specifications on the market, such as copper busbars or aluminum busbars with a processing width of less than 125mm and a thickness of less than 16mm. These technical parameters jointly determine the wide application and high-efficiency performance of the equipment in the field of busbar processing.
Structural composition
The structural composition of the busbar punching, cutting and bending machine is relatively complex but scientific and reasonable. The hydraulic electric pump with solenoid valve is the power core, providing strong and stable hydraulic power for punching, cutting and bending. The busbar punching machine is equipped with advanced punches and dies, which can punch holes of different shapes and sizes according to needs. The busbar cutting machine is responsible for accurately cutting the busbar. Its cutting blade is made of hard material and the cutting device is stable to ensure the flat cutting surface. The busbar bending machine is driven by hydraulic cylinders and other components to achieve various bending operations of the busbar. The workbench, as a processing platform, carries the busbar. Its surface is flat and has a positioning device to facilitate the placement and fixing of the busbar. The conversion switch is used to switch between different processing units. It is easy to operate and enables the equipment to flexibly switch between functions such as punching, cutting and bending.
Working principle
The working principle of the busbar punching, cutting and bending machine is a highly automated mechanical processing process. After the equipment is started, the processing parameters of the busbar, such as length, hole position, bending angle, etc., are first input through the control system. After receiving the command, the control system will accurately control the movement of each component. The hydraulic electric pump starts working to provide power for the punching machine, cutting machine and bending machine. Under the command of the control system, the busbar punching machine is positioned to the specified position and quickly punches out holes of the required shape. The busbar cutting machine moves to the corresponding position according to the set length and accurately cuts the busbar. After the busbar bending machine receives the bending instruction, the hydraulic cylinder pushes the bending die to bend the busbar to a preset angle. The whole process is efficient and accurate, realizing the automated processing of the busbar, greatly improving production efficiency and processing quality.
Automation and intelligence level
The busbar punching, cutting and bending machine has many automated and intelligent functions. The automatic positioning function is one of its highlights. The equipment can accurately identify the processing coordinate position of the busbar through advanced sensors and control systems, ensure the accuracy of the processing position, and avoid the error of manual positioning. The automatic mold change function is also very convenient. When it is necessary to process holes of different shapes and sizes or perform different bending methods, the equipment can automatically change the corresponding mold without manual intervention, greatly improving production efficiency and flexibility. In terms of intelligence, the equipment has an intelligent diagnosis function and can monitor its own operating status in real time. Once a fault or abnormality occurs, it will alarm and display fault information in time, which is convenient for maintenance personnel to quickly check and repair, ensuring the stable operation of the equipment and reducing downtime.
Application and Cases
In substation construction, busbar punching, cutting and bending machines play an important role. Take a large 500kV substation project as an example. The project needs to process a large number of copper and aluminum busbars. The traditional processing method is inefficient and difficult to guarantee accuracy. After the introduction of the busbar punching cutting and bending machine of SUNSHINE, an advanced busbar machine manufacturer, the situation has changed greatly. The equipment quickly and accurately completes the busbar punching. The shape and size of the hole fully meet the design requirements. The length of the cut busbar is accurate and the bending angle is strictly controlled within the specified range. This not only greatly improves the construction efficiency and shortens the construction period, but also ensures the connection quality and electrical performance of the substation busbar, laying a solid foundation for the stable operation of the substation. In the construction of the distribution room, the equipment also performs well. It can flexibly process the busbar according to the different layouts and needs of the distribution room, making the installation of electrical equipment in the distribution room more convenient and efficient, and the reliability and safety of the overall electrical system are significantly improved.
In the field of rail transit electrical equipment manufacturing, busbar punching, cutting and bending machines are also indispensable equipment. For example, the electrical equipment manufacturing company of Jinan Metro Vehicles in China relies on this equipment for processing when producing busbars required for subway traction converters. The equipment efficiently completes the punching task of the busbars, and the punched holes are accurate and correct, which provides convenience for the subsequent installation of electrical components. The cut busbars are of precise length, ensuring the compactness and rationality of the internal structure of the electrical equipment. The bending function bends the busbars into complex shapes, meeting the strict requirements of subway vehicle electrical equipment for busbar spatial layout. Due to the outstanding performance of the equipment, the rail transit electrical equipment produced by the company has stable and reliable performance, which has been widely recognized by customers and provides a strong guarantee for the safe operation of rail transit.
Comparison with traditional busbar processing methods
(1) Improved processing accuracy and efficiency
Traditional busbar processing methods often rely on manual operation and simple tools, which makes it difficult to ensure processing accuracy and inefficient. Manual measurement and positioning are prone to errors, and the accuracy of punching, cutting and bending is greatly affected by the operator's technical level. The busbar punching, cutting and bending machine relies on advanced control systems and precision components to achieve punching accuracy of ±0.1mm, cutting accuracy of ±0.1mm, and bending angle accuracy within ±0.2°. In terms of efficiency, the punching speed is about 30 times/minute, and the fastest cutting speed is 30 meters/minute, which is far higher than traditional methods. It greatly shortens the production cycle and can quickly meet the needs of large-scale busbar processing, providing efficient and accurate processing guarantees for the production of electrical equipment.
(2) Reduced labor costs and labor intensity
Traditional busbar processing requires a lot of manpower, and each link is closely dependent on worker operation, with high labor costs and high labor intensity. Workers need to perform repeated punching, cutting and bending actions for a long time, which makes them easily fatigued and may also cause work-related injuries due to improper operation. The busbar punching, cutting and bending machine realizes automated processing, and only a few people are needed to operate and control the equipment, which greatly reduces the number of workers. It automatically completes various processing tasks, and workers only need to perform simple loading, unloading and monitoring work, which greatly reduces the labor intensity. At the same time, the labor cost is effectively reduced due to the reduction of labor, saving a lot of labor cost expenditure for the enterprise.
(3) Impact on product quality and production safety
The busbar punching, cutting and bending machine is of great significance to product quality and production safety. Its high-precision processing ensures that the busbar hole position is accurate, the cutting surface is flat, and the bending angle is precise, making the busbar connection more secure and the electrical performance more stable, thereby improving the overall quality of electrical equipment. In terms of production safety, traditional processing is prone to safety accidents due to manual operation errors, while the automated operation of this equipment reduces the contact between people and dangerous parts. It is equipped with safety protection devices, such as emergency stop buttons, etc. Once an abnormality occurs, it can stop running in time, effectively avoiding work-related accidents, ensuring the personal safety of operators, and creating a safe and stable environment for production.
