When buying a CNC busbar machine, you must pay attention to several special busbar bending

SUNSHINE busbar machine manufacturing company has been focusing on the research and development of CNC busbar machines and the manufacturing of portable hydraulic busbar machines, serving more than 900 power company customers each year, and providing customized busbar bending, punching and cutting automated CNC busbar processing solutions for customers in more than 20 countries.

In terms of busbar bending technology, SUNSHINE Busbar Machine Manufacturing Company has always been a leader in the industry, with rich experience in handling various special busbar bending and special bending mold customization. Now, our busbar bending technology engineer Robin will share several special busbar bending types and their solutions with you based on actual customer cases.

“Hello everyone, I’m Robin. I’m responsible for the research and development of busbar bending technology and the formulation of customer bending application solutions at SUNSHINE Busbar Machine Manufacturing Company. Today I will mainly share several special busbar bending types and their corresponding solutions.”

In my daily work, I often communicate with our customers about the processing of the bending process and mold customization solutions on the busbar drawings to ensure the high-precision bending effect required by customers and to ensure that the actual bending effect and the bending parameters on the busbar drawings have zero error. But one day when I was discussing the customer’s bending technology solution with our sales manager Lisa, I found that we had been doing this wrong: my job should be to intervene in the sales quotation stage, not after the customer contract is signed.

Lisa, her sales team and I have discussed and communicated with each other about this issue, and we found the reason: customers prefer to compare market prices and get a satisfactory quote before communicating with our technical team about the realization of busbar bending effect. If the customer has rich experience in busbar processing, then this problem will no longer be a problem. However, our busbar processing machine factory encounters more traders or service providers who purchase busbar machines for their customers. This problem is very serious and may cause the end customer to be unable to achieve the bending effect on the busbar drawing.

Off Topic: We know that the main factors that determine customers’ purchase of busbar machines are price and processing quality. Generally speaking, if you directly find the source factory of the busbar machine, the general price of the busbar processing machine with conventional standard configuration is: the price of busbar special equipment with a maximum processing capacity of 12mm*160mm is in the range of $5700-$6700, the price of busbar special equipment with a maximum processing capacity of 16mm*250mm is in the range of $7500-$8500, and the price of busbar special equipment with a maximum processing capacity of 20mm*300mm is in the range of $8300-$9500. If the quotation you get is higher than this price range, it is most likely a trader. Of course, if the quotation you get may be lower than this price range and you choose to place an order, I must honestly tell you that you may have bought refurbished second-hand equipment or low-quality equipment.

For the above problems, we cannot influence our customers to choose a suitable supplier: first communicate the technical solution and then get a quotation. This is too difficult for most traders or service providers, and it is obviously unrealistic.

After many communications, my team and I have come up with a small solution to ensure that our customers, or customers who want to buy busbar machines for their own use, or customers who help their customers buy busbar processing machines, can buy the busbar machines they like and are suitable for end customers: popularize several special bending types. After you master these common special bending types, when you ask for quotes from suppliers, you can simultaneously confirm whether it can be achieved, whether special molds are required, and quote separately from the equipment with conventional standard configurations. This will help you compare and choose a good busbar machine manufacturer.

There are three main types of busbar bending. The first is a single bending type, where only one bend is made on a busbar; the second is a multi-bending type with a bending distance greater than 40mm, where multiple bends are made on a busbar, and the distance between them is greater than 40mm; the third is a multi-bending type with a bending distance less than 40mm, where multiple bends are made on a busbar, and the distance between them is less than 40mm.

Single bend type and multi-bend type busbar bend with a bend distance greater than 40mm can be processed using conventional bending dies, such as the commonly used R3, R5, R10, R50, R80, etc. If you have other bending radius mold requirements, such as R6, R12, R20, etc., you can contact our factory sales manager Lisa (Email: lisa@busbarmachine.co) to quickly customize special radius bending dies.

The third type of bending with a bending distance of less than 40mm is our focus today, and it is also what you need to learn through this article. Below I will tell you about the actual case of our customers.

Through the drawings provided by Vietnamese customers, we found that the customer mainly processes 12.7mm*127mm busbars, presses two bends with a radius of R12, and the distance between the two bends is 48-12.7=35.3mm. Faced with this situation, we cannot achieve the drawing effect required by the customer through conventional customized R12 bending molds. From the following two R12 mold drawings with a width of 30mm, we can know that it is impossible to achieve.

The solution we finally provided to customers was to use a Z-shaped mold, but the special mold also needed to be customized according to the drawings, including bend spacing, bend radius, etc., and the busbar thickness must also be considered.

Through the drawings provided by Dubai customers, we found that the customer mainly processes 3mm*40mm busbars, presses 20 bends with a radius of R3, and the distances between the two bends are 18-3=15mm and 26-6=20mm respectively. For this drawing, we face two problems, one is that the bend distance is too small, and the other is that there are many bends, and the processing efficiency is low.

The solution we finally gave to the customer was to customize a special one-time forming bending mold according to the drawing, and the busbar bending effect desired by the customer can be achieved by pressing 5 times. Of course, many people will say that since they all customize one-time bending molds, why not press 5 bends at one time? Our Dubai customers also asked the same question.

We know that customers can use busbar-specific equipment with a maximum processing capacity of 12mm*160mm to process 3mm*40mm busbars. However, if 5 bends are pressed at one time, the bends on both sides of the busbar and the middle bend will definitely be unevenly stressed, and a uniform effect cannot be achieved. This requires increasing the pressure of the hydraulic pump and upgrading to a busbar-specific machine with a maximum processing capacity of 16mm*250mm. Although the efficiency can be increased by 4 times, the cost of equipment upgrade is about US$2,000. At this time, it depends on the customer to weigh the efficiency and cost.

By understanding several special bending types and their solutions, the problem of mismatch between actual application and equipment configuration can be greatly solved, and production needs can be truly met. However, for busbar machine buyers, especially traders or service providers who purchase on behalf of customers, we hope that everyone will not only limit themselves to selecting busbar machine manufacturers based on price, but also consider the technical strength and professionalism of busbar machine suppliers, so that the purchased busbar machine can truly meet the actual processing needs.

If you are looking for a suitable busbar machine manufacturer or CNC busbar machine supplier, please contact us now and tell us your busbar processing requirements. We will provide you with the best quotation based on our senior busbar processing machine manufacturing experience.

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