Bending of Coiled Copper and Aluminum Busbars
Solution Overview
This is a fully automatic integrated solution for enameled wire laser stripping and 3D bending. It adopts a 6-axis industrial robot as the material transfer hub, flexibly connecting laser stripping and bending processes to replace traditional linear production lines with manual transfer. It supports complex 3D bending of round and flat wires, suitable for multi-variety mass production such as new energy drive windings and transformer leads.
The production line adopts a flexible island layout, integrating the full workflow: unwinding, straightening, feeding, laser stripping, bending, cutting and palletizing. With full servo CNC closed-loop control and quick changeover capability, it delivers an overall cycle time of ~10 seconds per piece, realizing unmanned production from coil input to finished product output.
Active Unwinding & Servo Feeding
Servo active unwinder with 200–500kg load capacity, dual-station design for non-stop coil change. Multi-roller straightener achieves XY bi-directional straightening with straightness ≤1.0mm/500mm. Servo feeding accuracy ±0.1mm/100mm, max speed 50m/min.
In-line Laser Stripping Unit
Equipped with CO₂ or fiber laser and scanning galvanometer, with fully enclosed optical protection and fume extraction system. Programmable power and scanning parameters, bright & scratch-free copper surface after stripping, adaptable to various enamel thicknesses.
6-Axis Robot Transfer Hub
Industrial robot with 1.5–1.8m reach, 10–20kg payload, repeatability ±0.05mm. Flexible gripper at end effector handles inter-process material transfer, breaking linear layout limits and enabling multi-station parallel operation.
3D Bending Forming Main Unit
8–12 axis full servo rotary bending mechanism, turntable rotation 0°–330°, supports in-plane, 3D and twist bending with multi-axis synchronous forming. Tool holder carries multiple die sets with servo auto-switching, angle accuracy ±0.5°.
Precision Cutting & Palletizing
Servo shearing or die punching mechanism, burr-free smooth cut end, length accuracy ±0.2mm. The same robot finishes unloading and palletizing, with optional vision guidance for precise positioning.
Modular Flexible Production Line
Independent modular design of each unit, flexible station addition and upgrade. One-click program changeover within 3 minutes for same wire diameter. Compatible with multi-variety mass production, operable by single technician.
Equipment Specs
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