Four servo axes,
one sequence
Every part is a program of feeds, rotations and bends, repeated until the form is finished and cropped off the wire.
Feed
Grooved rollers draw wire off the coil through the straightener and meter out each straight length.
Rotate
The boom turns the bend head around the wire, so the next bend can land in any plane and the part comes out in 3D.
Bend
The bend pin swings around the centre die to the programmed angle, then backs off for the next feed.
Crop
The head lifts and shears the finished part off at the die. The wire is already in place for the next one.
The machine, close up
Photographed in our workshop. Tap any image to open the full-resolution original.
The control package
- Servo drives
- 2 × B&R ACOPOS P3 multi-axis servo drives running the feed, rotate, bend and crop axes.
- Controller
- B&R X20 PLC with mapp Axis motion control and stored part programs.
- Operator
- Touch HMI with B&R mapp screens, hard-wired Start/Stop/Reset and emergency stop.
- Safety
- Dedicated safety relay circuit on its own labelled bank, with drive power isolated through K1.
- Power
- Weidmüller and WAGO 24 V supplies with a PULS DC UPS, so the controller rides through dips and shuts down cleanly.
- Build
- Ducted and labelled throughout: mains isolator, breakers, PSUs, I/O, safety, relays and PE bank.
Re-engineered and programmed in-house
This machine was rebuilt start to finish by our own South African team. We did the engineering, the cabinet build and wiring, the motion code and the operator screens in our workshop.
The people who built it are the people you call for support.
- Engineering
- Cabinet build & wiring
- B&R motion programming
- HMI screens
- Commissioning
Got a wire bender on an old controller?
We keep the mechanics that still work and replace the drives, controller and HMI that don't. Talk to us about a rebuild like this one.