busbar-automation-equipment-busbar-production-line-processing-machine-automatic-assembly-system
Brand: Benfa
Country of origin: China
Technical Support: Longlife
Application: Busway / bus duct trunking systems Switchgear & power distribution cabinets New energy vehicle battery packs Photovoltaic & energy storage systems EV charging stations Data center power distribution Transformer & industrial power manufacturing
Turnkey busbar production line — storage to packaging in one intelligent flow
24-hour lights-out production — robotic loading, saves ~80% labor
9–11 auto die changeover — φ4.3–35 mm punching, no manual tool changes
CAD-driven CNC bending — reads DXF/STEP directly, ±0.1° accuracy
±0.1 mm repeat positioning — consistent, high-quality busbars
Full traceability — QR code on every busbar, linked to MES
Smart nesting — ~15% material saving
4-gun riveting module — 200 mm pitch, ≈400 s cycle
In-line quality control — 5000 V hi-pot test + auto packaging
Compact footprint — saves ~60% floor space, cloud monitoring
busbar automation equipment
busbar production line
automatic busbar assembly machine
busbar processing machine
busbar fabrication system
a.Our busbar automation equipment is a complete, turnkey busbar production line covering the entire manufacturing process — from intelligent material storage, robotic loading, punching, cutting, and bending, to milling, laser marking, automatic assembly, riveting, inspection, and packaging.
b. As an integrated busbar fabrication system, it replaces manual handling and fragmented processes with one continuous, intelligent workflow.
c.The line supports both copper and aluminum busbars, delivering micron-level precision, 24-hour unattended production, and full traceability for switchgear, busway trunking, and new energy vehicle applications.
1. Intelligent material warehouse
Automated stereoscopic storage with gantry + vacuum-suction handling achieves unmanned material flow — from "man finds material" to "material finds man" — with 99.9% inventory accuracy and WMS integration with MES/ERP systems.
2. Robotic loading & handling
Robotic arms grip and transfer material with millimeter-level positioning, eliminating overhead-crane and manual handling risks.
3. All-in-one punching & cutting
This busbar processing machine integrates punching, embossing, and shearing in a single setup. It carries 9–11 die sets with fully automatic changeover, covering φ4.3–35 mm hole diameters and 3–15 mm busbar thickness.
4. Milling & laser marking
Automatic milling of arc corners and chamfers removes burrs and eliminates high-voltage corona discharge risks. Laser marking engraves a unique QR code and serial number on each busbar for full lifecycle traceability.
5. CNC bending center
As an advanced automatic busbar assembly machine companion, the bending module reads CAD drawings directly (DXF/STEP), auto-generates programs, and completes Z/U/L-type complex bends with ±0.1° accuracy — continuous feeding, no mid-cut, 40% efficiency gain.
6. Automatic assembly & riveting
The compact busbar assembly module pre-loads covers, copper bars, insulation strips, and side plates, then rivets automatically with 4 guns, PLC-controlled 200 mm pitch, and 400-second cycle time for 1500–6000 mm busbars.
7. Online inspection & packaging
Integrated 5000 V hi-pot tester, automatic stretch-film wrapping, cutting, and stacking complete the closed-loop production.
8. Smart control system
MES dashboard with real-time monitoring, intelligent nesting (genetic algorithm, ~15% material saving), cloud connectivity, and remote PC/mobile monitoring.
automatic busbar assembly machine.
1. Mechanical structure and drive system.
a. The busbar automation equipment is built as a continuous busbar production line composed of an intelligent material warehouse, robotic loading, punching/cutting station, milling/laser marking station, CNC bending center, automatic assembly and riveting section, online inspection station, and packaging/stacking area.
b. The intelligent storage module uses a stereoscopic material warehouse with gantry handling and vacuum suction grippers, enabling unmanned loading, automatic inventory tracking, and WMS integration with MES/ERP systems.
c. The automatic busbar assembly machine module uses an 80 × 80 mm aluminum profile frame with 304 stainless-steel rollers, pneumatic top/bottom clamping cylinders, and a synchronized belt center clamp for stable transport.
d. The riveting section is equipped with four self-piercing rivet guns arranged symmetrically on the top and bottom of the busbar, driven by a servo system to maintain center alignment on different busbar widths.
e. The bending center uses a fully electric CNC drive with a servo-controlled bending arm and automatic backgauge, enabling continuous feeding without mid-cut and Z/U/L-type complex forming.
f. The auxiliary support system includes adjustable roller tables, linear guides, and pneumatic side clamps to prevent deformation of long busbars during punching, bending, and riveting operations.
2. Electric control system.
a. The busbar processing machine adopts PLC control with a 10-inch color touch-screen HMI, robot teach pendants, and dedicated servo drives for each functional module.
b. The safety system includes safety light curtains, emergency stop buttons, door interlocks, and an alarm buzzer; any light-curtain interruption immediately stops the corresponding station.
c. The punching station supports automatic die changeover across 9 to 11 die sets, with die position feedback and automatic lubrication controlled by the PLC.
d. Laser marking engraves a unique QR code on each busbar after processing, linking the product to MES data for full lifecycle traceability.
e. The intelligent nesting software uses a genetic algorithm to optimize cutting layout, achieving approximately 15% material saving compared with manual layout.
f. The system supports DXF/STEP drawing import, automatic program generation, remote monitoring via PC or mobile, and cloud-based production-data reporting.
3. Technical indicators.
a. Overall line layout: material warehouse + loading → punching/cutting → milling/marking → bending → assembly/riveting → inspection → packaging/stacking.
b. Working length range: 50 – 6000 mm.
c. Busbar thickness range: 3 – 15 mm.
d. Punching diameter range: φ4.3 – 35 mm.
e. Bending thickness range: 3 – 12 mm.
f. Repeat positioning accuracy: ±0.1 mm.
g. Bending angle accuracy: ±0.1°.
h. Production takt: approximately 60 seconds per piece.
i. Labor saving: approximately 80% (from 5–6 workers to 1 operator).
j. Efficiency gain: approximately 50% compared with traditional fragmented layout.
k. Floor space saving: approximately 60% compared with traditional layout.
l. Riveting pitch: 100 mm at head, then 200 mm standard; PLC auto-compensates at tail.
m. Riveting cycle time: approximately 400 seconds per piece for 1500–6000 mm busbars.
n. Inspection: 5000 V hi-pot tester, 3-phase 3/4/5-wire selectable.
o. Applicable products: copper busbars, aluminum busbars, busway trunking, switchgear components, NEV battery busbars.
