In power equipment manufacturing workshops, busbar processing machines are indispensable “precision craftsmen.” They precisely complete key processes such as punching, cutting, and bending of copper and aluminum busbars, directly determining the connection reliability of the power system. Punching and cutting, as fundamental steps in busbar processing, embody both the wisdom of mechanical design and the scientific principles of material processing. This article will guide you through an in-depth understanding of the working mechanisms of these two core functions, revealing the secrets to the efficient operation of busbar processing machines.
Busbar Punching Principle
The core of the busbar machine’s punching function is to achieve “chip-free forming” through mechanical or hydraulic power, processing precise holes on the busbar that meet installation requirements. Unlike traditional drilling, punching uses a “cutting” principle, utilizing the cooperation of the punch and die to apply enormous pressure instantaneously to separate the material. This method is not only more efficient but also avoids metal debris contamination and hole diameter accuracy deviations caused by drilling.
Structurally, a punching mechanism mainly consists of a power source, a punch, a die, a positioning device, and a guiding mechanism. The power source is the “heart” of the punching process. Currently, most mainstream busbar processing machines use hydraulic drive (such as the SUNSHINE MX602K series busbar punching machine from CNC busbar machine manufacturer SUNSHINE), because it can provide stable and adjustable pressure output. When the hydraulic system starts, the hydraulic pump pressurizes the hydraulic oil, and the flow of the oil is controlled by a solenoid valve, pushing the piston of the hydraulic cylinder to drive the punch in a linear motion. Compared to mechanical drive, the advantage of the hydraulic system is its smooth pressure curve, which allows for flexible pressure adjustment according to the busbar thickness (usually 1-30 mm), ensuring that thin busbars are not deformed while thick busbars are punched through smoothly.
The accuracy of the punching process depends on the “perfect coordination” between the punch and the die. The punch is typically made of high-strength alloy tool steel, achieving a hardness of HRC60 or higher after heat treatment, ensuring durability against repeated impacts. The die is designed to be detachable based on common hole diameters, with its inner diameter 0.05-0.1 mm larger than the punch diameter. This small gap reduces friction and ensures smooth, burr-free punched edges. The positioning device uses stops and scales to accurately position the busbar. Some high-end models are also equipped with CNC positioning systems, controlling positioning accuracy within ±0.1 mm to meet the installation requirements of complex cabinets. Once the busbar is fixed, the punch descends rapidly under hydraulic power, completing the punching process through a “shearing-separation” procedure. The entire action takes only 0.5-1 second, far exceeding the efficiency of traditional processing methods.
Busbar Cutting Principle
If punching is like “opening up the joints” for the busbar, then cutting is like “shaping and slimming” it. Its core is to separate the busbar to predetermined dimensions through controllable force or energy. Depending on the processing requirements, busbar processing machines primarily offer two cutting functions: mechanical shearing and plasma cutting, suitable for processing busbars of varying thicknesses and materials.
Mechanical shearing is the most widely used cutting method. Its principle is similar to scissors cutting fabric, but it employs a more efficient lever and hydraulic transmission structure. The shearing mechanism consists of an upper blade, a lower blade, a blade holder, and a power unit. The upper blade is fixed to a movable blade holder, while the lower blade is fixed to the machine base. The cutting edges of the two blades are at a certain angle (usually 3°-5°). This design concentrates the shearing force at the blade contact point, reducing the compression deformation of the busbar. During shearing operations, the hydraulic system drives the blade holder downwards, and the upper and lower blades work together, using a combined “compression-shear” action to separate the busbar along the cutting edges. To ensure cutting quality, the blade gap needs to be precisely adjusted according to the busbar thickness—for thin busbars under 10 mm, the gap is controlled at 0.1-0.2 mm; for thick busbars over 10 mm, the gap is adjusted to 0.2-0.3 mm. This prevents blade chipping and ensures a smooth cut.
Conclusion
It is worth noting that modern CNC busbar machine incorporate intelligent control technology for both punching and cutting. Through a PLC control system and touchscreen interface, operators can preset processing parameters, and the equipment can automatically complete a series of actions such as positioning, power output, and reset. This not only reduces human error but also enables continuous multi-process processing. Simultaneously, the equipment is equipped with overload protection and emergency stop devices to effectively prevent equipment damage caused by hard materials or operational errors, ensuring the safety of the processing.
