Busbar Bending Machine 101

The busbar bending equipment features a platform and three processing units for punching, cutting, and bending, providing versatility for all bending operations. Operators can use the machine to punch, cut, and bend copper or aluminum busbars separately or simultaneously.

What is a Busbar Bending Machine

A Busbar Bending Machine, also known as a Busbar Machine or Busbar Bending-Cutting-Punching Machine, is a piece of equipment used for the processing of various specifications of copper and aluminum busbars. It is equipped with punching, shearing, and bending processing stations, designed with three independent hydraulic systems and separate working platforms. The punching, cutting, and bending units of the busbar bending machine operate simultaneously without interference. The same machine can perform punching, cutting, and bending processes separately or simultaneously.

Functions of Each Processing Station of the Busbar Bending-Cutting-Punching Machin/Busbar Machine

Punching Station – Six-Mode Rotary Table

The punching station punches holes in workpieces according to punching coordinates controlled by servo motors and PLC, allowing for continuous positioning punching of multi-hole workpieces efficiently and precisely.

The bi-directional positioning design of the punching station, combined with the tabletop scale, ensures more precise hole punching, improves work efficiency, and reduces the generation of defective products.

The punching station is designed with various processing modes such as free mode and template mode. In the free mode, punching coordinates for the X and Y axes can be directly inputted without manual measurement. In template mode, standard copper bar punching can be easily achieved by simply inputting a few values.

The punching turntable adopts a six-mode integral turntable made of nodular cast iron, which is solid and reliable, ensuring the absolute alignment of the upper and lower dies, increasing the concentricity of the dies, reducing the need for frequent die changes by workers, improving production efficiency, reducing labor intensity, and significantly extending the service life.

Shearing Station

The shearing station adopts a dual-column dual-blade shearing structure, with the upper and lower blades installed vertically and in parallel, resulting in clean cuts without burrs or deformation, presenting an aesthetically pleasing appearance, and producing no waste material.

Both sides of the shearing blade are sharp and can be replaced. The adjustment allowance (number of uses) is large, reducing later maintenance costs.

The shearing positioning stop can precisely position the shearing length, allowing for convenient and quick adjustment, significantly improving work efficiency and accuracy without the need for marking lines during the working process.

The shearing station controls the shearing stop size automatically through servo motors and PLC, ensuring convenience and efficiency.

Bending Station

The bending station adopts a double-layer working table design with servo motors, high-precision guide rails, and screw-controlled bending length positioning function, combined with angle control by LC, enabling positioning of multi-segment lengths and multiple angles for multi-bend processing.

The open-style bending provides good visibility, convenient placement and removal of busbars, high bending accuracy, ease of observation, and easy operation.

The bending length is controlled by servo motors, automatically positioning the material stop, allowing for multiple angles and positions to be programmed. Through the coordination of servo motors, PLC, and CNC touchscreen, automatic positioning of the three stations is achieved.

Various processing modes such as A-bend, B-bend, three-bend, and free bend are preset, ensuring more uniform bending during flat bending and embossing, improving the repeatability of positioning accuracy during batch production.

Classification of Busbar Bending Machines

These busbar mending machines are generally classified as standard Busbar Bending Machines, CNC Busbar Bending Machines, combination Busbar Bending Machines, and portable Busbar Bending Machines. All these types of Busbar Bending Machines have three units for punching, shearing, and bending, and the working stroke of each processing unit can be easily adjusted. They can conveniently and quickly perform cutting, punching (round holes, elongated holes), flat bending, vertical bending, embossing, and other processes on copper and aluminum busbars, shortening processing time and improving production efficiency. The equipment is suitable for the switchgear, transformer manufacturing industry, used for processing busbars of various specifications.

Performance Characteristics of Busbar Bending Machines

1. The busbar bending machine has three processing units: punching, shearing, and bending, which can perform punching, cutting, and bending operations separately, as well as special processes such as flattening, embossing, cable joint pressing, and button flower pressing.
2. Easy to use, with significantly higher production efficiency than traditional busbar processing equipment.
3. The working stroke of each unit can be easily adjusted, reducing auxiliary processing time and improving production efficiency.
4. The punching and shearing units adopt a vertical processing method, flexible and convenient operation, with flat cutting resulting in smooth workpieces.
5. The bending unit adopts a horizontal approach and can achieve flat and vertical bending by changing the dies.
6. By changing the dies, various processing functions such as embossing, flattening, cable joint pressing, and button thread pressing can be realized.
7. Equipped with casters for easy movement by adjusting the four support feet.
8. The equipment has a built-in solenoid valve oil pump, with a full copper motor, high working efficiency, and stable operation.
9. Accurate measuring rulers are provided on each workbench, facilitating precise busbar processing.
10. Each workstation is equipped with foot switches and button switches, making operation more convenient and efficient.

Applications of Busbar Bending Machines

Busbar Bending Machines are easy to operate, user-friendly, and highly efficient, mainly used in the switchgear and transformer manufacturing industry for processing copper and aluminum busbars of various specifications.

The working stroke of each unit of the Busbar Bending Machine can be easily adjusted, reducing auxiliary processing time and improving production efficiency. It is an ideal processing equipment for the high and low-voltage electrical appliance manufacturing industry and is suitable for construction sites, railways, mines, ports, docks, and other fields.

Structure and Working Principles of Busbar Bending Machines

The machine consists of a frame, punching unit, shearing unit, bending unit, hydraulic station, electrical system, and molds.

The frame is welded from square steel pipes with sufficient strength and rigidity. The punching, shearing, bending, and electrical components are mounted on the frame, with the hydraulic station placed inside the frame. The working principle of the machine is as follows: the motor (provides power to the pump) pumps oil (generates high-pressure hydraulic power), the relief valve (controls pressure), the solenoid directional valve (transmits hydraulic oil to each cylinder), and the cylinder (realizes punching, shearing, and bending operations).

The motor rotates to provide power to the pump, which generates high-pressure oil. When the solenoid directional valve is not working, the high-pressure hydraulic oil is directly returned to the oil tank. When the solenoid directional valve is working, the pressure oil provided by the pump enters the different working chambers of the cylinder through the directional valve, thereby causing the cylinder to perform reciprocating motion.

Installation and Precautions Before Starting the Busbar Bending Machine

Machine Installation

1. When the machine needs to be hoisted during transportation and installation, ropes should be hung on the lifting corners of the machine.
2. The machine should be installed on a sturdy and level ground.
3. The machine should be installed in a spacious processing area to meet the working conditions of the machine.
4. Check whether the machine installation is level, and adjust the four leveling bolts if necessary to level the machine.
5. The power line must be properly connected without obstructing work.
6. The power supply for the machine is three-phase four-wire 380VAV+PE.

Precautions Before Starting

1. Before starting, check whether the motor rotation direction is consistent with the specified direction (consistent with the pump rotation direction).
2. If the indoor temperature is below 10°C, the pump should be operated empty for 5 minutes before starting.
3. During operation, if the machine works continuously for more than 5 hours, the oil temperature may become too high, causing chemical changes in the oil additives and resulting in valve or pump failures. Working at high temperatures will significantly shorten the life of the sealing rings and cause leaks. Therefore, when working continuously for a long time, the operator should stop the machine for 5 minutes or longer until the oil temperature drops to the specified temperature before restarting.
4. To ensure the absolute cleanliness of each sliding part of the device, because the sliding parts are subjected to a relatively large frictional force, good lubrication is required to ensure smooth operation during up and down or forward and backward movements.
5. The screws of the fixed device may loosen when too much pressure is applied, so the operator should regularly check them (recommended: monthly intervals) and tighten them.

Safety Operation Precautions of Busbar Bending Machines

Before Operation

1. Ensure a safe working environment around the machine before operation.
2. Do not operate the machine with scarves or coats that may pose a safety hazard.
3. Work in the correct manner to stop and avoid danger quickly in case of malfunctions.
4. Power requirements: three-phase four-wire 380V±10%+PE.
5. If the ambient temperature is below 10°C, the machine should be operated empty for 5 minutes before working.
6. Before operation, carefully read this user manual to thoroughly understand the structure, performance, and operation methods of the machine.
7. The 303 series requires the addition of No. 46 anti-wear hydraulic oil 80KG, while the 503 and 803 series require the addition of No. 46 anti-wear hydraulic oil 100KG before starting up.
8. Calibrate the upper and lower dies of the punching dies to ensure that the dimensions and shapes match perfectly.

During Operation

1. Installation, debugging (die adjustment, blade gap adjustment), or disassembly of molds must be carried out by personnel familiar with the machine, following the specified procedures.
2. When the machine is working, do not place hands or any part of the body between the upper and lower dies (blades) or between the bending dies to avoid accidents.
3. Keep all debris and tools off the workbench to prevent them from being crushed into the molds or blades, causing equipment damage and accidents.
4. As multiple operators can operate this machine, there must be someone designated to supervise production.
5. Select the appropriate blade gap and bending radius according to the thickness of the copper (or aluminum) bar before operation.
6. When changing molds, the machine must be stopped to avoid danger.
7. Be cautious when the slider is descending during operation to prevent accidents.
8. Regularly check the sharpness of the blades and punching dies. If dull, sharpen or replace them promptly.
9. Keep the hydraulic fluid clean and the oil passages unobstructed, and grease each unit’s moving parts at each shift.
10. Electrical and wave pressure components are the basis for ensuring the normal operation of the equipment. If any abnormal phenomenon is found, the machine should be stopped immediately for inspection to eliminate potential hazards.

After Operation

After operation, the machine must be safely shut down in the following order:

1. Turn off the working buttons of each unit.
2. Turn off the power switch on the control panel.
3. Turn off the main circuit breaker.
4. Turn off the workshop power switch.

Read More: Busbar Bending Formula & Busbar Size Calculation Formula