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Features of the busbar bending machine

Rotational measurement system in busbar bending machine

The busbar bending machine is one of our busbar bending machines and part of our complete line of busbar manufacturing machines . A rotary encoder with a pulse rate of 3600 pulses per revolution is directly connected to the rotating plates of the bending unit. Since these plates are attached to the back of the busbar and rotate with it during the bending process, the rotation rate is directly transmitted to the encoder (5 pulses per degree), after which the bending unit controller adjusts the bending degree in real time and terminates the process when the set bending angle is reached.

Linear measuring system for busbar bending machine

A digital ruler, consisting of a magnetic strip and a digital reader attached to the end of the piston rod, measures and controls the piston feed rate during each bending operation. This system ensures bending repeatability with an accuracy of up to 5 microns, allowing for consistent bends across multiple bends. Instead of entering the angle at the beginning, the operator can also enter the stroke length directly on the device’s screen. It should also be noted that the roller plate, mounted in the moving jaw of the bending unit, dynamically rotates during bending along with the bar, a design feature that prevents stretching of the underside. The bar advances over other surfaces, leaving a line on the underside of the bar during bending. Other features of the bending unit include the ability to mount a bar with various radii on the fixed jaw of the bending unit, improving the accuracy of the bending arc with varying material thicknesses.

Twisting bending mold in a busbar bending machine

In some cases, when connecting a busbar to a desired component, we encounter problems with the busbar’s orientation being misaligned with the installation site. Because of this, most customers must use multiple busbars to achieve this connection. The solution offered by PAYAPRESS is a «twisting bending mold,» which allows for rotating a 10 x 60 mm busbar by up to 90 degrees, which proves very useful when necessary. This complex bending can be performed on PAYAPRESS busbar bending machines. For best results, the busbar should be pre-cut to the correct size using a busbar cutting machine before twisting .

Edge bending mold for busbar bending machine

In some cases, for buses with different widths and thicknesses, instead of using two buses perpendicular to each other, it is possible to take advantage of the ability to bend copper at an angle of up to 90 degrees.

Z-shape in a busbar bending machine

As you know, some copper busbar applications require two bends to be made very close together. Many busbar bending machines typically have a bending limit of 60 mm due to the use of tools called «bending rollers» to create closely spaced bends. If the electrical panel design requires a bend to be made at a closer distance, a more efficient bending pattern—the so-called «Z-bend»—should be used.