Integrated Wire and Bar Bender
2.Operation Mode: Intelligent CNC automatic control
3.Bending Mode: Automatic straightening, cutting, and bending
4.Rebar Diameter Range: φ5–13 mm
5.Bending Shape: Square, rectangle, polygon
6.Bending Precision: ±1 mm
7.Power Supply: 380V / 50Hz / 3-phase
8.Control System: CNC touch screen management system
9.Production Efficiency: 2000–2600 hoops/hour
10.Main Materials: High-strength industrial steel frame
11.Application: Hoop production and construction reinforcement processing
Product Description
Integrated Wire and Bar Bender - Advanced CNC Rebar Processing Solution
The construction and infrastructure industries demand precision, efficiency, and reliability in steel reinforcement processing. Shandong Zhongji Luyuan Machinery Co., Ltd., established in 2016 with a registered capital of RMB 50 million, addresses these needs through its high-performance Integrated Wire and Bar Bender. This enterprise-grade CNC system combines wire and bar processing capabilities in one compact unit, handling materials from φ5–13 mm with exceptional bending precision of ±1 mm.
With generation effectiveness coming to 2000–2600 loops per hour and requiring as it were one administrator, this machine drastically decreases labor costs whereas keeping up steady quality. The progressed CNC touch screen administration framework empowers consistent exchanging between handling modes, making it perfect for large-scale ventures over railroads, interstates, bridges, and urban construction.
Trusted by industry pioneers counting China Railroad Gather and CSCEC, our arrangements are traded to about 100 nations worldwide.
What Makes Our Integrated Wire and Bar Processing System Stand Out
Your construction projects require equipment that delivers consistent results without constant supervision. Our dual-function processing system eliminates the need for separate wire and bar bending machines, cutting your equipment investment by half while doubling operational efficiency.
The intelligent CNC control system stores multiple processing parameters with one-touch recall. You can switch from processing φ6 mm wire to φ16 mm bar in seconds without manual recalibration. This flexibility is crucial when handling diverse reinforcement requirements on busy job sites.
The curve straightening method ensures raw material emerges perfectly straight before entering the bending stage. Combined with synchronized servo-motor technology, this prevents the dimensional drift common in older hydraulic systems. Your finished stirrups maintain ±1° angle accuracy across thousands of units.
Technical Specifications
| Parameter | Specification |
|---|---|
| Wire Processing Range | φ6–φ12 mm |
| Bar Processing Range | φ14–φ16 mm |
| Wire Straightening Method | Curve straightening |
| Bar Loading Method | Automatic |
| Maximum Hoop Diagonal Length | 1500 mm |
| Maximum Wire Feeding Speed | 100 m/min |
| Maximum Bar Feeding Speed | 70 m/min |
| Maximum Bending Speed | 1100 °/s |
| Length Accuracy | ±1 mm |
| Angle Accuracy | ±1° |
| Equipment Power (Main Unit) | 38 KW |
| Equipment Power (Production Line) | 50 KW |
| Production Efficiency | 1 ton/hour (2000–2600 hoops/hour) |
| Operating Personnel | 1 person |
| Floor Area (Main Unit) | 4.4 m × 1.7 m |
| Floor Area (Production Line) | 20 m × 4.5 m |
| Power Supply | 380V / 50Hz / 3-phase |
Key Advantages for Your Operations
Unified Processing Capability
This combined machine replaces two separate systems. You process both thin wire for lightweight structures and thick bars for heavy reinforcement using the same equipment. The operational cost savings extend beyond purchase price to reduced maintenance contracts and spare parts inventory.
Superior Production Efficiency
Fully automatic integration of feeding, straightening, bending, and cutting eliminates manual handling between stages. Production output reaches 6–10 times manual bending rates. Your crew completes in one shift what previously required three days.
Space and Investment Optimization
The compact 4.4 m × 1.7 m footprint fits into existing workshops without facility expansion. The high-strength industrial steel frame withstands 24-hour continuous operation in demanding environments. Lower initial investment compared to separate systems means faster return on capital.
Precision Engineering
The PLC intelligent control system with touch screen interface stores unlimited processing patterns. High-grade alloy steel bending mandrels maintain consistent accuracy across production runs. This repeatability is essential when fabricating reinforcement cages where dimensional tolerance affects structural integrity.
Operational Simplicity
One-key switching between wire and bar modes eliminates complicated setup procedures. Your operator manages the entire production line from the control panel. Reduced training requirements mean new staff become productive within days rather than weeks.
Primary Application Scenarios
Infrastructure and Bridge Construction
When you're building high-speed railway foundations or bridge decks, you need stirrups that meet strict structural tolerances. Our system produces high-tensile reinforcement with the consistency required for projects where safety standards are non-negotiable. The robust design performs reliably in outdoor conditions with dust and temperature fluctuations.
Precast Concrete Manufacturing
Modular housing factories benefit from the machine's ability to rapidly switch between reinforcement patterns. Just-in-time production becomes practical when setup changes take seconds instead of hours. You reduce inventory costs by producing exact quantities as needed.
Commercial Construction Projects
Large-scale building developments require massive quantities of uniform stirrups and mesh bars. The 1 ton/hour processing capacity keeps pace with concrete pouring schedules. Consistent quality across thousands of units ensures structural compliance throughout multi-story construction.
Quality Assurance and Performance Verification
Your investment deserves proven reliability. Every Integrated Wire and Bar Bender unit undergoes comprehensive testing before shipment. Geometric repeatability tests ensure the 1,000th stirrup matches the first unit's dimensions precisely.
The servo-motor load test runs continuously for 72 hours, simulating months of operational stress. This identifies potential component weaknesses before the machine reaches your facility. Software collision detection prevents tool damage during complex bending sequences, protecting your investment from operator error.
High-resolution encoders provide real-time feedback to the PLC controller. The system compares actual feed length against programmed specifications continuously. Production stops automatically if deviations exceed ±1 mm, preventing entire batches from falling outside tolerance.
Voltage stability testing ensures the CNC controller retains all stored parameters during power fluctuations. Your production data remains safe even in areas with unreliable electrical infrastructure. This reliability is critical for remote construction sites.
Frequently Asked Questions
Q: How does the system handle switching between different wire diameters?
A: The quick-change roller configuration adjusts straightening pressure automatically based on computerized diameter presets. You input the material specification through the touch screen, and the machine recalibrates bending radius within seconds. No manual adjustment of mechanical components is required.
Q: What maintenance schedule should we expect?
A: Bending mandrels require inspection every 500 operating hours. High-wear components typically need replacement after processing 2,000–3,000 tons, depending on material hardness. The straightforward design allows your maintenance team to perform routine servicing without specialized training.
Q: Can this machine process stainless steel or galvanized materials?
A: Yes, the system handles these materials effectively. For optimal surface finish and extended tool life with galvanized wire, we recommend chrome-plated rollers. This prevents zinc transfer and maintains corrosion resistance on finished components.
Q: What is the typical energy consumption compared to separate machines?
A: Modern integrated servo drives with regenerative braking consume 20–30% less power than separate hydraulic units. The 38 KW main unit operates efficiently during production, with automatic power reduction during idle periods. Lower energy costs contribute to faster investment recovery.
Q: How is precision maintained across long production runs?
A: The servo feedback system monitors every operation cycle. If actual measurements drift from programmed specifications, the PLC makes micro-adjustments automatically. This closed-loop control maintains ±1 mm length accuracy throughout shifts without operator intervention.
Q: What happens if we need to process special-shaped stirrups or hooks?
A: The system supports custom bending sequences through the touch screen interface. You can save unlimited processing patterns for specialized applications. Complex geometries including multi-angle bends and hooks are produced with the same precision as standard rectangles.
Contact Us for Your Processing Solution
Ready to transform your reinforcement processing efficiency? Our technical team will help you configure the ideal system for your Integrated Wire and Bar Bender requirements. Contact us at sales2@shandongluyuan.com to discuss specifications and installation planning.
