CASE STUDY
Cut-to-Length Busbar Bending
Solution Overview
Integrated Busbar Bending Line
The solution combines material loading, accurate positioning, CNC bending, springback compensation and finished-part unloading into a coordinated production process. The reference line also demonstrates a protected industrial production environment with dedicated processing and handling zones.
Material Range
Copper & Aluminum Busbars, 2.0–5.0 mm
Typical Width
8–30 mm straight cut sections
Applications
Switchgear, Storage & Industrial Control
Production Process
1. Cut-to-Length Busbar Bending Workflow
STEP 01–02
Loading, Positioning & Clamping
Place cut busbars on the loading station, align them accurately and secure the workpiece before forming.
STEP 03–05
Precision Multi-Stage Bending
Perform L, U, Z, offset, height-difference and multi-angle bends with programmable sequences and springback compensation.
STEP 06
Finished-Part Unloading
Use manual unloading for the simplified configuration or conveyor transfer and automatic stacking for automated production.
Equipment Configuration
2. Main Equipment Modules
01 · LOADING & POSITIONING
Accurate Material Preparation
Manual loading table or automatic storage rack, with front and rear positioning stops plus left and right centering for stable feeding and repeatable dimensions.
02 · CNC BENDING
Servo-Controlled Precision Forming
Multi-axis servo bending with controllable forming force, continuous multi-step forming and dedicated anti-marking or protective tooling.
03 · CONTROL
Touchscreen CNC Programming
Store 2,000+ programs and quickly recall matching parameters for flexible multi-specification production.
04 · OUTPUT
Manual or Automated Unloading
Choose manual part removal for a simple setup, or conveyor transfer plus automatic stacking to reduce operator intervention.
Solution Selection
3. Two Main Configuration Options
OPTION 01 · COST-EFFECTIVE
CNC Semi-Automatic Busbar Bending Machine
For small and medium batches, frequent product changes and conventional busbar processing. The operator loads the cut strip, while the machine performs automatic clamping and bending.
Reference performance: bending angle ±0.2°; length tolerance ±0.15 mm.
OPTION 02 · HIGH-THROUGHPUT
Fully Automatic Cut-to-Length Busbar Bending Line
For large-volume standardized production with automatic storage, feeding, positioning, continuous multi-station bending and finished-part stacking.
Production focus: one-person line supervision, reduced manual handling and strong part-to-part consistency.
Technology & Traceability
4. Core Technical Advantages
MATERIAL ADAPTATION
Copper & Aluminum Specific Parameters
Optimize forming parameters for different materials to reduce edge collapse or cracking while protecting insulated surfaces.
FLEXIBLE PRODUCTION
Recipe Storage & Fast Changeover
Store a large number of product programs and recall matching parameters for rapid changeover without repeated setup.
SMART FACTORY READY
Traceability, Vision & MES
The reference system supports dual-track material feeding, four laser stations for QR marking, IV4 vision inspection, MES integration and CE/SGS compliance documentation.
OPTIONAL FRONT-END / BACK-END
Pre-process: punching, corner cutting, chamfering and deburring. Post-process: inspection, stacking and packaging.
Equipment Specs
Applicable Material & Form
Pre-cut copper & aluminum busbars (straight bars, rigid short/long strips)
Processing Size Range
Thickness 1–12mm, Width 10–60mm
Bending Capability
L-shape, U-shape, Z-shape, height offset, multi-angle compound bending
Bending Accuracy
Angle ±0.2°, dimensional tolerance ±0.15mm
Mass Production Yield
≥99% (CNC closed-loop control)
Product Catalog
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