New 3 Speed Extended Open Busbar Machine

As a five-process integrated processing machine, this New 3 Speed Extended Open Busbar Machine innovatively integrates a professional embossing unit and a small bending unit on the basis of traditional shearing, punching, and bending functions. This design not only fully covers the general processing needs of high- and low-voltage switchgear, but also forms a precision machining workflow through the seamless integration of the five processes. It effectively eliminates positioning errors and time losses caused by transferring workpieces between different machines, enabling one-stop, high-precision production from raw materials to ready-to-assemble parts.

By significantly increasing the fast forward and reverse speeds, the New 3 Speed Extended Open Busbar Machine greatly shortens the production cycle time. This improvement not only increases the effective capacity of a single machine but also reduces the time required for continuous manual operation, creating favorable conditions for optimizing production shifts and lowering per-piece labor costs.

The New 3 Speed Extended Open Busbar Machine adopts a unique dual manual/automatic operation mode. During normal operation, it benefits from the precision and efficiency of full CNC control. If the control system requires maintenance or experiences a temporary malfunction, the operator can switch to an independent manual mode, ensuring that critical production tasks continue without interruption. This effectively eliminates the risk of unexpected production downtime caused by CNC system issues and ensures reliable order delivery.

For different bending requirements, the equipment provides a steplessly adjustable protection device for large and small bending forces. Heavy loads are used for large bends and lighter loads for small bends, thereby reducing damage to the molds.

With interchangeable bending dies, irregularly shaped busbars up to 12 mm thick can be processed, with a minimum span of 50 mm.

The system supports three advanced bending control modes: parametric input mode, intelligent calculation mode (trigonometric function), and limit mode.

The bending station adopts a high-rigidity open-type independent column structure. It features a large bending punch head with a built-in double slide-groove design. Dies with radii from 1–50 mm (R-angles) can be customized, and interchangeable punch heads allow the production of bent copper-clad aluminum busbars and busbars with various bending radii. For special R-angle requirements, complete die customization services are available.

This punching unit adopts a six-arm turret-type die frame with an open-angle structure, providing a clear processing view and intuitive operation. The die frame integrates dedicated positioning devices for longitudinal and transverse oval holes, and a specially designed station can permanently hold chamfering dies, enabling rapid switching between multiple functions.

Six sets of commonly used dies can be installed simultaneously, covering most daily processing requirements and significantly reducing die change frequency. All die mounting holes feature an integrated high-rigidity design and precision machining, ensuring extremely high concentricity at each station. This results in uniform pressure distribution, greatly reducing abnormal mold wear and significantly extending the service life of the entire die system.

This rapid shearing unit is 1.5 times more efficient than conventional equipment. Processing the same batch of workpieces can save approximately one-third of the time, reducing labor input and significantly lowering labor costs.

The unit adopts patented dual guide-groove technology. Its unique upper and lower blade configuration (vertical movement of the upper blade and a fixed lower blade) ensures a stable, precise, and misalignment-free shearing process, delivering three key advantages:

Time-saving: Suitable for material thicknesses from 3–17 mm with no gap adjustment required.

Material-saving: High cross-sectional perpendicularity allows direct installation, resulting in high material utilization and first-pass yield.

Labor-saving: The optimized structure significantly reduces tool wear, lowering replacement frequency and sharpening costs while also reducing operational complexity and labor intensity.

This unit represents a reliable investment designed for long-term cost reduction and improved efficiency.

This embossing station features a unique mechanical structure and stepless pressure control. Through interchangeable molds, it can quickly switch between multiple functions such as embossing, punching (two or four holes), chamfering, and crimping.

This design eliminates the complex processes and scattered equipment required in traditional production. It not only improves processing efficiency but also greatly reduces manpower requirements by simplifying the production workflow, providing key technical support for achieving up to a two-thirds reduction in labor costs.

This bending unit offers strong process versatility and can accurately produce various complex irregular shapes used in ring main units and environmental protection cabinets, as well as special-specification U-shaped bends.

Its innovative design allows the large bending station and the small bending module to operate collaboratively and synchronously. This enables parallel processing of two operations, significantly shortening the overall processing cycle while greatly improving equipment utilization and production efficiency.

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