Detailed Explanation of the Core Structure and Functions of 3D CNC Wire Bending Machine

The 3D CNC wire bending machine is an automated device that achieves high-precision 3D forming of wire.

The core structure and workflow of the 3D CNC wire bending machine are as follows: The wire is first fed by the wire feeding frame, then conveyed to the machine body and straightened by the straightening mechanism. It is then precisely fed to the processing area of ​​the machine via the wire feeding box. Subsequently, the basic bending angle is completed through the coordinated action of the coiling action and the wire feeding shaft. The rotating head shaft achieves multi-dimensional angle forming through flexible rotation. Finally, the finished product is cut off by a servo-controlled cutter, immediately initiating the processing of the next product.

ANTISHICNC 3D CNC wire bending machine

The stable operation and high-precision forming of the equipment rely on the coordinated operation of its core structures. Its main components and detailed functions are as follows:

Core Structure of 3D CNC Wire Bending Machine

1. Rotary Arm

The rotary arm is the core actuator of the 3D CNC wire bending machine, enabling spatial forming. It consists of a high-precision servo motor, a high-strength rotary arm body, and a wire fixing clamp. Its core function is to drive the fixed wire to complete angular forming in 3D space through flexible rotation at any angle of 360°. During operation, the clamp firmly fixes the end of the wire, and the rotary arm rotates precisely around its own axis or a designated center according to preset program instructions. This allows for the basic forming of complex three-dimensional structures such as rings, spirals, and multi-directional interlacing, with a rotational accuracy within ±0.1°, ensuring the consistency and accuracy of spatial angles. It is a key structure for the equipment to break through planar bending and achieve three-dimensional processing.

2. Corner Bending Machine

The corner bending machine is a functional component specifically responsible for bending and shaping wire angles and curvatures. It consists of a corner bending drive motor, replaceable corner bending dies, and an angle adjustment mechanism. Its core function is to achieve precise wire bending. Different bending radii (R-position) require corresponding dedicated corner bending dies (the die’s compatibility range typically covers R0.5-R20mm, supporting quick disassembly and replacement) to meet the curvature requirements of different products. During operation, the corner bending machine applies uniform pressure to the wire through the die according to the angle parameters set in the program, completing various corner bending shapes such as 90°, 135°, and rounded transitions. It can also be linked in real time with the rotating arm and wire feeding actions to ensure precise matching of the corner position and angle with the overall forming structure, avoiding problems such as fold line deviation and irregular curvature.

3. Cutting Blade

The cutting blade is a key component for precisely cutting the wire after forming. Driven by a servo motor, it consists of a moving blade, a stationary blade, a blade holder, and a buffer protection mechanism. Its core function is to quickly and smoothly cut the wire according to programmed instructions after all 3D forming actions are completed, forming a complete finished product. The cutting blade is made of high-strength wear-resistant alloy to ensure a smooth, burr-free, and deformation-free cut surface. The servo motor precisely controls the cutting speed and force, and the buffer mechanism reduces the impact force during cutting, protecting the blade and extending its service life while ensuring the accuracy of the cutting position (cutting error ≤ 0.05mm). Simultaneously, it is strictly synchronized with the wire feeding and forming actions, achieving continuous automated “forming-cutting” operation and improving production efficiency.

4. Wire Feeding Box

The wire feeding box is the core component responsible for the quantitative and uniform feeding of wire. It integrates a servo wire feeding motor, transmission rollers, a length measuring encoder, and a wire clamping device. Its core function is to precisely feed the straightened wire to the processing area of ​​the machine according to the preset parameters of the control system. The servo motor provides stable power, the transmission rollers and clamping device work together to ensure that the wire is fed without slippage or deviation; the length measuring encoder collects the wire feeding distance data in real time and feeds it back to the control system, achieving millimeter-level precision wire feeding (feeding accuracy up to ±0.05mm), ensuring the consistency of the length of each segment of processed wire, and providing a precise raw material basis for subsequent forming and cutting.

5. Straightening Mechanism

The straightening mechanism is the “pre-processing core” of wire processing, consisting of a straightening cylinder, multiple sets of staggered straightening rollers (or straightening blocks), a spacing adjustment knob, and a fixed support. Since coiled wire is prone to bending, twisting, and internal stress during storage and transportation, the straightening mechanism uses the squeezing and guiding of multiple sets of rollers to comprehensively straighten the wire. Operators can adjust the roller spacing to accommodate wires of different diameters (typically ranging from 0.5-16mm), ensuring the wire receives a uniform radial force as it passes through the straightening cylinder, gradually eliminating internal stress and ultimately outputting wire with satisfactory straightness (straightness error ≤0.1mm/m). This avoids deviations in subsequent forming accuracy caused by wire bending, laying the foundation for high-precision processing.

6. Drivers

The driver is the “power command converter” of the equipment and a core component of the servo system. It mainly consists of a signal processing module, a power amplification module, and a feedback adjustment module. Its core function is to convert the digital program commands issued by the control system (computer) into specific operating commands for each servo motor (wire feeder, rotating arm, angle bender, cutter, etc.), including motor speed, direction, start/stop timing, and operating precision control. The performance of the driver directly affects the processing accuracy and stability of the equipment. It has a fast response speed (usually ≤1ms), high control precision, and can receive feedback signals of motor operating status in real time, dynamically adjusting the output commands to ensure the synchronization and accuracy of the actions of each component. It is similar to the role of a frequency converter in a common AC motor, but adaptable to higher precision positioning and motion control requirements.

7. Computer (Core of Control System)

The computer is the “brain” of the 3D CNC wire bending machine, consisting of an industrial-grade host, a touch screen display, and dedicated control software. Its core functions are reflected in three aspects: First, program arrangement. Operators can directly input parameters such as the 3D dimensions of the workpiece, bending angle, wire feed length, and cutting position through the touch screen, or import CAD drawings to automatically generate processing programs, supporting program storage, retrieval, modification, and batch editing; Second, real-time control. The control software parses program instructions and sends precise control signals to each driver, coordinating the timing of the entire process, including wire feeding, straightening, forming, and cutting, ensuring seamless connection between each stage; Third, status monitoring. The display shows the equipment’s operating status, processing progress, and fault alarm information (such as wire jamming, mold abnormalities, motor failures, etc.) in real time, allowing operators to monitor production status, handle problems promptly, and ensure production continuity.

8. Wire Feeder

The wire feeder is the fundamental component of the equipment for supplying wire, consisting of a stable support, wire reel, tension adjustment device, guide wheel assembly, and anti-tangling mechanism. Its core function is to support the coiled wire and provide a stable and continuous supply of raw materials for subsequent processing. The tension adjustment device balances the tension during wire output, preventing excessive tension from causing wire stretching and deformation, or insufficient tension from causing wire loosening. The guide wheel assembly guides the wire smoothly along a fixed path to the straightening mechanism, preventing wire deviation and tangling. The anti-tangling mechanism effectively prevents the coiled wire from becoming loose or knotted during output, ensuring the continuity and stability of wire feeding.

9. Protective Cover

The protective cover is a core safety component of the equipment. Made of high-strength sheet metal, it fully covers the processing area of ​​the machine, the cutting mechanism, and other hazardous parts. It is equipped with a safety door lock, a transparent observation window, and an emergency stop button. Its core functions are: first, to ensure operator safety and prevent accidents caused by wire ejection, tool movement, or parts splashing during processing, meeting industrial production safety standards; second, to protect the precision components inside the equipment, preventing damage to core components such as servo motors, encoders, and transmission mechanisms from dust, oil, and external impacts, extending the equipment’s service life; and third, to facilitate production monitoring. The transparent observation window allows operators to observe the entire wire forming and processing process in real time without affecting production status control or interfering with normal equipment operation.

Please feel free to contact us bender@antishicnc.com anytime if needed. ANTISHICNC has professional staff ready to answer your questions and meet your needs.