How to operate a copper busbar punching, cutting and bending machine

Copper busbar punching, cutting, and bending machines (often simply called “busbar processing machine” or “copper busbar machine”) are high-efficiency busbar processing equipment integrating multiple functions, and are essential equipment for small and medium-sized high and low voltage switchgear manufacturers.

The SUNSHINE copper busbar machine comes in three models: SS-30-3CNC, SS-50-3CNC, and SS-80-3CNC, suitable for processing copper or aluminum busbars with maximum dimensions of 12*160mm, 16*250mm, and 20*300mm respectively.

Product Catalog: 3-in-1 Busbar Punching, Cutting, and Bending Machine

If this is the first time installing the equipment, please first inspect all parts of the equipment, checking for loose screws, electrical wiring, and other components, and tighten them accordingly. (Note: During transportation, bumps and jolting may cause screws to loosen.)

After inspecting the equipment, inject AW46 hydraulic oil (Hydraulic oil replacement specifications) and install the foot pedal switch（Common Fault Repair）. Next, connect the power supply and start the equipment. If the equipment does not work properly upon first power connection, please check if the power phase sequence is reversed. If so, reverse the power phase sequence and restart the equipment.

Before formally testing the equipment, please carefully read the operating instructions provided by the manufacturer and take photos of the equipment parameters and mold parameters with your mobile phone as backup.

Secondly, after starting the equipment, run it for several cycles without loading any workpieces to check whether the movement of each component is normal, whether there are any abnormal noises, and whether the punching unit, bending unit, and cutting unit are working smoothly.

1. Select a suitable punching die according to the busbar drawing and install it on the turret. When installing the punching die, ensure that the punch head and bottom die are aligned and directly below the punching rod. Incorrect operation will damage the punching die.
2. Use the scale on the equipment to calibrate the busbar punching coordinate position.
3.  Double-check the punching die specifications and position to ensure everything is correct.
4. Place the upper copper busbar and activate the foot pedal switch to perform the punching process.Repeat the above steps to perform repeated punching.

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1. First, install the mold of the corresponding model number onto the bending unit via the touchscreen. Then, use a wrench to secure the mold and prevent movement.

2.  Set the bending angle and other parameters, and use the limit magnetic block to determine the bending position of the busbar.

3.  Use the foot pedal switch to control the angle by adjusting the stroke of the bending cylinder. Trial bends may be necessary for fine-tuning.

4. After bending is complete, the upper mold returns to its original position, and the formed workpiece is removed.

1. Calibrate the busbar cutting position using the scale on the cutting unit.
2. Place the copper busbar under the cutting die and tighten the screws to secure the busbar.
3. Start the cutting action using the foot switch or two-hand buttons. The blade will press down, cleanly cutting the copper busbar.

Common problem: How to properly repair a hydraulic piston (hydraulic pump) that exceeds the stroke limit

After processing, first reset each working unit of the equipment to its original position, then turn off the equipment power, and finally close the main valves of the air and hydraulic power sources.

Simultaneously, remove copper shavings and waste from the worktable, molds, and waste bins. Wipe the equipment surface and guide rails with a soft cloth and apply anti-rust oil. Wipe the used molds clean, apply anti-rust oil, and return them to the mold rack for proper storage.

For beginners, it is strongly recommended to start practicing under the guidance of an experienced technical engineer, beginning with the simplest straight-line cutting and single-hole punching. After mastering the equipment’s characteristics and safety precautions, then proceed to more complex multi-process and bending operations.

The control panels and specific operations may vary slightly between different brands and models of equipment. Please be sure to carefully read and follow the manufacturer’s instruction manual. (Contact us to obtain the equipment instruction manual.)

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