How to Control a Flat Wire Bending Machine

How to Control a Flat Wire Bending Machine

A flat wire bending machine is a type of mechanical equipment that can bend metal wire into various shapes and specifications.flat wire bending machine It can be used to create a variety of products, including springs, electrical wires, furniture and more. It uses a robotic arm to automate the forming process, improving production efficiency and product quality. It can also be quickly adjusted to meet different product requirements.

For many metal forming applications, tolerances must be kept tight.flat wire bending machine This is especially true in the case of flat wire bending, where high-strength copper or steel coils are subjected to several steps before a final product is manufactured. In order to achieve these tolerances, a number of tools and alternate processes are employed, from grinding to drawing, forming, cutting and more. These processes often require a significant amount of time and effort, and even the slightest deviations in a part can lead to expensive rejects and waste materials.

In addition to a close adherence to tolerances, another important issue in flat wire bending is the ability to maintain accurate bend consistency. To this end, many shops use a paper printout of the desired bend profile and a set of gages that are inserted into the die or sets of dies to ensure that the profile is followed. Although this method is effective, it can be time-consuming and tedious. In addition, it is not always possible to accurately measure the bend angle on a finished piece of flat wire.

Fortunately, modern feedback control methods can be applied to solve this problem. The key is to obtain sensor information from the straightening operation, which can be used to calculate state variables of the bending machine and thus improve the performance of the control system.

The first step in this approach is to determine the change of the pre-curvature D0 of the coil after straightening, using an offline measurement. This value is fed into the feedforward controller, which calculates a reference trajectory zR,0(t) including the positions of the three movable straightening rollers. The resulting control signal is then corrected with closed-loop control in the straightening stage and feeds into the bending process.

This method is more accurate than a simple paper printout, and it can provide the data needed to correct the position of the bending rollers in real time. However, the sensors must be integrated into a special design for this to work. Previously, a measurement concept that incorporated load cells was used, but this method had a number of disadvantages.

In a new, improved version of this technology, a sensor was designed that was capable of measuring the roller process force in the straightening stage, while simultaneously monitoring the bending machine position. This sensor was inserted laterally into a forked body that also served as a guide for vertical movement. This design eliminated the need for additional gages, and it was able to detect the actual roller force directly and accurately. As a result, the error in the feed force was greatly reduced, and the bending performance of the machine was improved significantly.

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