The principle of CNC busbar punching machine

SUNSHINE busbar machine manufacturing company is a Chinese CNC busbar processing machine manufacturer, providing busbar processing solutions for bending, punching and cutting for more than 900 busbar manufacturers worldwide. Sunshine Busbar Machine Manufacturing Co., Ltd. has nearly 20 years of experience in busbar processing technology research and development, and its processing effect and processing accuracy in busbar bending and punching are well received by customers.

Last time, our busbar bending technical engineer Robin shared the common sense and real customer cases about busbar bending. This time, our busbar punching technical engineer Luis will share the common sense and real customer cases about busbar punching.

“Hello everyone, I’m Luis. I’m currently working at Sunshine Busbar Machine Manufacturing Company, responsible for the technical research and development of busbar punching and the debugging of CNC punching PLC system. The sharing of Robin, the technical engineer of busbar bending technology, was great last time! He told me a lot of tips on how to share better, and I hope I can use them this time.”

“Today I will mainly share knowledge about busbar punching, including punching principles, CNC punching PLC system, common problems and their solutions. I hope that through this sharing, more people will understand the technology of busbar punching, and can communicate more smoothly with technicians when purchasing CNC busbar punching machines or customizing busbar punching molds.”

The principle of busbar punching is to use a busbar punching machine to punch the busbar, and through the cooperation of the punch and the die, a hole of specified shape and size is punched on the busbar.

The punch of the busbar punching machine moves downward under the action of pressure and aligns with the hole position of the die. When the punch enters the die, the metal part of the busbar is sheared off to form a hole.

When the punch contacts the busbar, the material begins to deform plastically. As the pressure increases, the material is gradually sheared and eventually a hole is formed. During the shearing process, the material will produce a certain elastic deformation, but it will eventually return to its original state to a certain extent.

The shape and size of the die determine the shape and size of the hole. The die needs to have high hardness and wear resistance to ensure long-term use without deformation. All our punching dies are made of SKD-11 steel and are heat-treated, with a lifespan 2-3 times that of 45# steel dies.

Conventional busbar punching machines require manual calibration and punching every time they punch. With the introduction of the PLC system, busbar punching machines can realize CNC automated operation, reduce human intervention, and greatly improve processing accuracy and efficiency. The PLC system consists of key components such as PLC controller, human-machine interface (HMI), servo motor and driver, and hydraulic system.

PLC realizes logical control of the machine through programming languages ​​(such as ladder diagrams and function block diagrams). Users can input and adjust processing parameters such as punching position, hole diameter, punching speed, etc. through HMI. PLC generates control signals based on these parameters to drive the servo motor and hydraulic system to perform corresponding actions.

Sunshine Busbar Machine Manufacturing Company has been continuously exploring and innovating in busbar punching technology. With the continuous breakthrough of punching technology difficulties and its adaptation to the ever-changing customer demands, our multifunctional busbar bending, punching and cutting machine equipped with servo positioning function has become the most popular busbar machine product for customers in the South American and Southeast Asian markets, and CNC busbar punching and shearing machine has become the new market favorite of customers in the United States and the Middle East with its 3D drawing import, online networking, high automation level and processing accuracy.

Before the development of the two busbar punching machines, we had to solve the technical problem of “how to solve the punching burrs or rough punching sections that customers are concerned about”? We did a lot of busbar punching test experiments, collected thousands of busbar punching data of different thicknesses, and finally solved it. The following figure shows the data of our experimental test results.

Through thousands of punching experiments, we found that under the same pressure, different G values ​​are required for punching busbars of different thicknesses, that is, the gap value (D-d) between the punch and the die. So based on this experimental conclusion, we set busbars of 12mm, 16mm and 20mm thickness as the dividing points, and configured 3 different types of busbar machines: SS-30-3CNC 300K equipment for punching busbars with a thickness of less than 12mm, SS-50-3CNC 500KN equipment for punching busbars with a thickness of less than 16mm, and SS-80-3CNC 800KN equipment for punching busbars with a thickness of less than 20mm, which completely solved the problem of burrs on the busbar punching section.

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.

Sunshine Busbar Machine Manufacturing Company is constantly innovating in busbar punching technology, reducing human intervention, improving processing accuracy and efficiency, and realizing the automation of busbar punching. When facing new problems or technical difficulties from customers, our unyielding spirit of innovation inspires us to overcome them one by one and provide more customers around the world with highly automated CNC busbar machines or busbar processing application solutions.

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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