Bending Tool Assembly for Busbar Processing

Product Specifications

Technical details and manufacturing context for Bending Tool Assembly

Definition

The Bending Tool Assembly is a critical component of the Busbar Processing Unit responsible for forming busbars into specific configurations. It typically consists of a bending mechanism, tool holders, and positioning elements that work together to create accurate bends according to engineering specifications, ensuring proper electrical connections and mechanical fit in switchgear, distribution panels, and other electrical equipment. The assembly is designed for use with copper or aluminum busbars, with a bending capacity of 120–200 mm² cross-section. It offers a bending angle range of 0–90 degrees, adjustable stops for repeatability, and a bending radius of 5–15 mm depending on the die set. Positioning accuracy is ±0.1 mm, and angle accuracy is ±0.5 degrees, critical for multi-bend assemblies. The operating pressure is 1.0–1.6 MPa, and the cycle time per bend is 3–8 seconds depending on material and angle. The power supply is three-phase, 380–415 V AC, 50/60 Hz (IEC 60038), with a motor power of 1.5–3.0 kW driving the hydraulic pump. The operating temperature range is -10 to 50 °C, and the protection class is IP54 (IEC 60529). The weight is 150–250 kg depending on configuration. Materials used include tool steel, carbide inserts, and hardened alloy steel. The assembly operates by applying mechanical force through hydraulic, pneumatic, or servo-electric actuators to deform busbars around a forming die or mandrel. The tooling is precisely aligned to create clean bends without damaging the conductive material. For procurement, verify model-specific values and standards with the legal manufacturer or supplier.

Working Principle

The assembly uses mechanical force applied through hydraulic, pneumatic, or servo-electric actuators to deform busbars around a forming die or mandrel. The tooling is precisely aligned to create clean bends at predetermined locations without damaging the conductive material or compromising its electrical properties. The bending process involves clamping the busbar, positioning it against adjustable stops, and then actuating the bending mechanism to achieve the desired angle. The die set determines the bending radius, and the system ensures repeatability through precise positioning and angle control.

Common Materials

Tool steel, Carbide inserts, Hardened alloy steel

Technical Parameters

Parameter	Typical range	Notes & selection driver
Bending Capacity	120–200 mm²	Cross-section of copper or aluminum busbar
Bending Angle Range	0–90 °	Adjustable stops for repeatability
Bending Radius	5–15 mm	Depends on die set
Positioning Accuracy	±0.1 mm	Ensures consistent bend location
Angle Accuracy	±0.5 °	Critical for multi-bend assemblies
Operating Pressure	1.0–1.6 MPa
Cycle Time	3–8 s	Per bend, depending on material and angle
Power Supply	380–415 V AC	Three-phase, 50/60 HzIEC 60038
Motor Power	1.5–3.0 kW	Drives hydraulic pump
Operating Temperature	-10–50 °C	Outside this range, hydraulic fluid viscosity changes
Protection Class	IP54	Dust and splash water protectedIEC 60529
Weight	150–250 kg	Depends on configuration

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Bending Punch Part
Applies force to deform the busbar against the die

Material: Tool steel
Bending Die Part
Forms the inner radius and shape of the bend

Material: Hardened alloy steel
Tool Holder
Secures and positions bending tools relative to the busbar

Material: Steel alloy
Back Gauge
Positions busbar accurately for consistent bend locations

Material: Steel with wear-resistant coating
Bending Actuator
Supplies the force that drives the punch into the busbar.
Clamping Mechanism
Holds the busbar down while the punch works, so the bend lands where the back gauge set it.

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Busbar Processing Unit

View system integration details

Manufacturers of Bending Tool Assembly

Manufacturer profiles associated with Bending Tool Assembly.

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Frequently Asked Questions

What materials can the Bending Tool Assembly process?

The assembly is designed for copper or aluminum busbars with a cross-section of 120–200 mm². The tooling materials include tool steel, carbide inserts, and hardened alloy steel, which are suitable for these conductive materials.

What is the bending angle range and accuracy?

The bending angle range is 0–90 degrees, with adjustable stops for repeatability. The angle accuracy is ±0.5 degrees, which is critical for multi-bend assemblies. Positioning accuracy is ±0.1 mm.

What are the power and pressure requirements?

The assembly requires a three-phase power supply of 380–415 V AC, 50/60 Hz (IEC 60038), with a motor power of 1.5–3.0 kW. The operating pressure is 1.0–1.6 MPa.

What environmental conditions can it operate in?

The operating temperature range is -10 to 50 °C. The protection class is IP54 (IEC 60529), meaning it is protected against dust and splash water. Verify specific limits with the manufacturer.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

Preliminary Technical Classification

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pressure:	Up to 200 bar hydraulic system pressure
other spec:	Maximum bending force: 50 kN, Minimum bend radius: 2x material thickness
temperature:	15°C to 40°C (operating ambient)

Bending Tool Assembly

Product Specifications

Applied To / Applications

Industrial Ecosystem & Supply Chain Structure

Application Fit & Sizing Matrix

Reliability & Engineering Risk Analysis

Compliance & Manufacturing Standards