全自动铝条折弯机是现代工业中实现铝条精密加工的核心设备，其通过集成机械、电气与软件技术，将铝条精准塑形成矩形、异型或圆弧框架。以下从机械结构、控制系统、工艺流程三大维度解析其工作原理。

　　The fully automatic aluminum strip bending machine is the core equipment for precision processing of aluminum strips in modern industry. It integrates mechanical, electrical, and software technologies to accurately shape aluminum strips into rectangular, irregular, or circular arc frames. The working principle is analyzed from three dimensions: mechanical structure, control system, and process flow.

　　一、机械结构：精密协同的物理执行系统

　　1、 Mechanical Structure: Precise Collaborative Physical Execution System

　　上料与定位模块

　　Loading and positioning module

　　自适应传送装置：铝条经上料传送带进入设备，两侧的转动调节盘通过伸缩弹簧与防滑条实现自动对中。例如，当5.5-24mm宽的铝条输送时，传感器实时检测位置偏差，驱动电机带动调节盘以±3mm的浮动范围调整，确保铝条居中。

　　Adaptive conveyor device: Aluminum bars enter the equipment through the feeding conveyor belt, and the rotating adjustment discs on both sides are automatically aligned through telescopic springs and anti slip strips. For example, when conveying aluminum bars with a width of 5.5-24mm, the sensor detects the position deviation in real time, and the driving motor drives the adjustment disc to adjust within a floating range of ± 3mm to ensure that the aluminum bars are centered.

　　接料机构：采用双气缸夹紧设计，前定位槽条与后定位槽条通过导轨滑块实现精准对接。当铝条尾部触发信号时，移动气缸以0.1mm精度推动后夹紧部件前移，完成铝条插角U型结构的自动续接，材料利用率提升15%。

　　Material receiving mechanism: Adopting a dual cylinder clamping design, the front positioning groove and the rear positioning groove are precisely docked through guide rail sliders. When the tail of the aluminum strip triggers a signal, the moving cylinder pushes the rear clamping component forward with a precision of 0.1mm, completing the automatic continuation of the U-shaped structure of the aluminum strip insertion angle, and increasing material utilization by 15%.

　　折弯执行机构

　　Bending actuator

　　伺服驱动折弯模组：由高刚性机身、四轴伺服电机及折弯刀头组成。以中空玻璃铝框加工为例，刀头角度通过谐波减速器实现0.1°分辨率调节，配合压力传感器实时反馈折弯力矩，确保2000×2000mm大尺寸铝框折角误差≤0.3mm。

　　Servo driven bending module: composed of a high rigidity body, a four axis servo motor, and a bending blade. Taking the processing of hollow glass aluminum frames as an example, the blade angle is adjusted to a resolution of 0.1 ° through a harmonic reducer, and real-time feedback of bending torque is provided by a pressure sensor to ensure that the bending angle error of the 2000 × 2000mm large-sized aluminum frame is ≤ 0.3mm.

　　多级变速系统：根据铝框尺寸自动调节转速，300×300mm小框折弯速度可达120次/分钟，而2000mm长边则降至30次/分钟以保障精度。

　　Multi speed transmission system: The speed is automatically adjusted according to the size of the aluminum frame. The bending speed of the 300 × 300mm small frame can reach 120 times/minute, while the 2000mm long side is reduced to 30 times/minute to ensure accuracy.

　　切割与下料装置

　　Cutting and cutting device

　　气动切割系统：采用双导柱气缸驱动锯片，切割压力通过比例阀精确控制。断口处配置毛刺清理模块，利用高速旋转尼龙刷实现0.5mm以内的毛刺去除。

　　Pneumatic cutting system: The saw blade is driven by a dual column cylinder, and the cutting pressure is precisely controlled through a proportional valve. Install a burr cleaning module at the fracture site, using a high-speed rotating nylon brush to remove burrs within 0.5mm.

　　自动卸料机构：完成加工的铝框经传送带输送至堆垛区，配备光电传感器检测堆垛高度，触发机械臂自动码放。

　　Automatic unloading mechanism: The processed aluminum frame is transported to the stacking area by a conveyor belt, equipped with photoelectric sensors to detect the height of the stack and trigger the mechanical arm to automatically stack.

　　二、控制系统：智能决策的神经中枢

　　2、 Control system: the central nervous system for intelligent decision-making

　　硬件架构

　　Hardware Architecture

　　主控制器：采用和利时MC1002R运动控制器，搭载ARM Cortex-A9双核CPU，支持RTEX总线实现32轴联动。例如，在四工位折弯机中，四组伺服轴同步误差控制在0.05mm以内。

　　Main controller: Adopting the Hollysys MC1002R motion controller, equipped with ARM Cortex-A9 dual core CPU, supporting RTEX bus to achieve 32 axis linkage. For example, in a four station bending machine, the synchronization error of the four sets of servo axes is controlled within 0.05mm.

　　伺服系统：松下A6N系列伺服驱动器，配合23位绝对值编码器电机，实现0.01mm的重复定位精度。

　　Servo system: Panasonic A6N series servo drive, combined with a 23 bit absolute encoder motor, achieves a repeat positioning accuracy of 0.01mm.

　　软件算法

　　Software algorithm

　　图形解析引擎：支持DXF、CAD等格式导入，自动生成折弯序列。例如，将正六边形铝框数据解析为6次折弯指令，每次旋转60°并补偿弹性回弹量。

　　Graphics parsing engine: supports importing formats such as DXF and CAD, and automatically generates bending sequences. For example, parsing the data of a regular hexagonal aluminum frame into 6 bending commands, rotating 60 ° each time and compensating for elastic rebound.

　　动态补偿模块：通过温度传感器监测机身热变形，实时调整折弯参数。在连续工作8小时后，系统自动补偿0.1-0.2mm的热胀冷缩误差。

　　Dynamic compensation module: monitors the thermal deformation of the body through temperature sensors and adjusts bending parameters in real time. After 8 hours of continuous operation, the system automatically compensates for thermal expansion and contraction errors of 0.1-0.2mm.

　　人机交互界面

　　Human-computer interaction interface

　　10.4英寸维纶触摸屏：集成图形化编程界面，操作人员可通过拖拽方式设定铝框尺寸、折弯角度等参数。例如，设定300×400mm矩形框时，系统自动计算对角线误差补偿值。

　　10.4-inch Velon touch screen: Integrated graphical programming interface, operators can set parameters such as aluminum frame size and bending angle by dragging and dropping. For example, when setting a 300 × 400mm rectangular box, the system automatically calculates the diagonal error compensation value.

　　远程诊断功能：支持以太网连接，工程师可远程调取设备日志，通过PLC程序回放功能复现故障过程。

　　Remote diagnostic function: Supports Ethernet connection, engineers can remotely access device logs, and reproduce the fault process through PLC program playback function.

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