Multifunctional 3 in 1 Busbar Machine
DGWMX 303E/503E/803E-3-S
Maximize Your Busbar Production Efficiency<br><br>
All-in-One CNC Busbar Processing Solution: Bend, Punch, Cut.
Maximize productivity & save floor space with LiJian’s integrated hydraulic 3-in-1 machine. Process copper & aluminum busbars for switchgear, transformers, and new energy applications.
Busbar Machine Detailed Description
1.Introduction
The CNC 3 IN 1 Busbar Processing Machine is a highly efficient and versatile all-in-one unit that seamlessly integrates punching, cutting, and bending; specifically designed for precision, it significantly reduces manual labor and setup time while simultaneously improving accuracy.
Moreover, its advanced CNC control ensures consistent quality and supports a wide range of copper and aluminum busbar sizes; consequently, it is ideally suited for electrical panel manufacturing, switchgear assembly, and transformer production.
Furthermore, with robust construction and full automation, this machine substantially enhances workshop efficiency and reliably meets complex project demands; ultimately, it represents a smart investment for fabricators aiming to streamline production, maintain consistent quality, and accelerate timelines.
2.Main Characteristic
- Equipped with a SIEMENS S7-40 PLC control system from Germany, which features an automatic shutdown function. This system precisely controls the down time of both the cutting and punching units, resulting in significantly greater stability and reliability compared to traditional relay systems.
- Furthermore, the punching unit incorporates a high-strength nodular cast iron turret-style turntable with 4/6/8 mold holes, crafted as a single, integral piece. Consequently, the mold holes (for molds precision-machined in our own processing center) achieve exceptional accuracy, with a clearance between molds and turntable of only 0.00-0.03mm. This dramatically improves concentricity, thereby extending mold life and reducing the frequency of mold changes.
- Additionally, an enhanced punching positioning system enables mechanical bi-directional location on both the X and Y axes. As a result, operators no longer need to cross-reference lines or make manual punching marks, which directly improves both operational efficiency and punching accuracy.
- For the cutting unit, its patented double upright pillar and dual-blade shear structure (Patent No. ZL201120262802.1) ensures superior performance. The upper and lower blades are installed in perfect vertical parallel alignment, guaranteeing smooth cuts, no waste material, and zero deformation even after prolonged use.
- The bending unit, meanwhile, utilizes a closed bending design. Its output point and force-bearing structure are connected to a robust 50mm thick beam, delivering far greater mechanical strength than open bending alternatives.
- Notably, bending angles are precisely controlled by the numerical control system. For Z-bends, operators simply enter H (vertical height) and L (hypotenuse length)—then the system automatically calculates the required angle. During operation, workers only need to input the desired angle and busbar thickness for fast, convenient processing. Moreover, the machine includes data storage and automatic error compensation functions.
- Beyond Z-bends, the bending unit can also process U-bends with a minimum center distance of 40mm.
- Regarding durability, the hydraulic oil tank is welded from 3mm thick steel plate and treated with phosphating. This process prevents oil deterioration and allows the hydraulic fluid to maintain its performance for longer.
- In terms of the hydraulic system, it employs an independent “one pump, one cylinder” design with three cylinders and three pumps working separately, ensuring they do not interfere with each other.
- All cylinder oil tubes are fitted with international Type-A connectors, making them both highly durable and easy to repair or replace.
- Finally, the machine is mounted on heavy-duty casters, providing easy mobility within the workshop.
3.Main parts
| 1 | Main Motor | Juliweite | 3 |
| 2 | Hydraulic Oil Cylinder | LIJIAN (MADE IN TAIWAN, China) | 3 |
| 3 | Electromagnetic reversing valve | FENGYI | 3 |
| 4 | Electromagnetic relief valve | FENGYI | 3 |
| 5 | AC contactor | SIEMENS | 3 |
| 6 | Thermal relay | SIEMENS | 3 |
| 7 | PLC | SIEMENS | 1 |
| 8 | Encoder | GUANGYU | 1 |
| 9 | Touch screen | PanelMaster | 1 |
4.Random Annex
Punching molds × 8（Φ7、Φ9、Φ11、Φ13、Φ17、Φ11×15、Φ13×17、Φ17×21）
Cutter × 1
Horizontal bending molds × 3
Embossing molds × 1
Random repair tool × 1
Standby seal ring × 1
Foot switch × 3
Why Choose the LiJian® 3-in-1 Busbar Machine?
Firstly, LiJian® combines nearly 20 years of specialized CNC machinery manufacturing expertise with innovative design.
Secondly, our 3-in-1 machine is the preferred choice for global electrical equipment manufacturers seeking reliability, precision, and exceptional value.
- Integrated Efficiency: Three independent hydraulic stations (bending, punching, cutting) operate without interference, dramatically increasing throughput.
- CNC Precision Bending: Features a Siemens PLC control system supporting automatic L, Z, U, and other complex bends with an error of only ±0.3°.
- Heavy-Duty Capacity: Process copper or aluminum busbars up to 20mm thick and 300mm wide with our largest model.
- Plug-and-Play Tooling: Comes standard with a comprehensive set of bending, punching, cutting, and embossing dies for immediate operation.
- Future-Proof Design: Easily upgradeable with servo motor systems for automated, full-CNC positioning and feeding.
Furthermore, technical Specifications & Model Comparison
Select the model that matches your production capacity. All models include three independent 4-7.5KW motors, a Siemens PLC for the bending unit, and a multi-language HMI mobile panel.
Feature / Model | DGWMX-303(Standard Duty) | DGWMX-503 (Medium Duty) | DGWMX-803 (Heavy Duty)** |
Max. Bending Thickness/Width | 12mm / 160mm | 16mm / 250mm | 20mm / 300mm |
Bending Angle Error | ±0.3° | ±0.3° | ±0.3° |
Max. Cutting Thickness/Width | 12mm / 160mm | 16mm / 250mm | 20mm / 300mm |
Punching Diameter Range | Φ4 – Φ30 mm | Φ4 – Φ30 mm | Φ4 – Φ30 mm |
Standard Punching Stations | 6 | 6 | 6 |
Hydraulic Cylinder Pressure | 300 KN | 500 KN | 800 KN |
Total Motor Power | 4 KW x 3 | 5.5 KW x 3 | 7.5 KW x 3 |
Power Supply (Customizable) | 380V, 50Hz (Standard) | 380V, 50Hz (Standard) | 380V, 50Hz (Standard) |
Additionally, Power Customization Available: We can customize motors and electrical systems for 400V/50Hz, 415V/60Hz, or other regional standards.
Standard Tooling Package & Customization
Therefore, each LiJian® 3-in-1 machine comes with a complete set of high-quality tooling, ready for production.
Standard Included Dies:
- Punching Dies (8 Sets): Φ7, Φ9, Φ11, Φ13, Φ17, Φ11×15 (oval), Φ13×18 (oval), Φ17×21 (oval).
- Bending Dies (5 Sets): R3, R5, R10, R80, and a U-Shape die.
- Other Tools (3 Sets): 1x Cutting Die, 1x Embossing Die, 1x Twist Mold (Optional).
Your Custom Solution: We Build to Your Blueprint
Firstly, send us your CAD drawing for a free technical analysis. Beyond standard tooling, we specialize in custom engineering to meet your exact needs:
- Custom one-time-forming bending molds for complex shapes.
- Special punching dies for rectangular, square, or unique geometries.
- Machine configuration for specific material grades or unique production workflows.
Secondly, Safe Operation & Punching Capacity Guide
⚠️ Critical Safety Notice: Do not exceed the recommended punching capacity for each die. Overloading can cause die fracture and machine damage.
Target Industries & Applications
Generally, the LiJian® 3-in-1 Machine is essential for fabricating busbars used in:
- High & Low Voltage Switchgear
- Power Transformers & Substations
- Distribution Cabinets & Panel Boards
- New Energy Systems (Photovoltaic Inverters, Energy Storage)
- Railway & Marine Electrical Systems
Why 3-in-1 busbar machine Partner with Shandong Lijian CNC Machinery?
Your Trusted Manufacturer Since 2005
Finally, as a factory-direct manufacturer, we control every step from design to assembly, ensuring top quality and competitive pricing. “LiJian®” stands for reliability in over 50 countries.
Further More, Our Commitment to You:
- Engineering Support: Get expert consultation from our in-house engineers.
- Quality Assurance: Rigorous testing of every machine before shipment.
- Comprehensive Training: Detailed operational and maintenance training provided (onsite or via video).
- Responsive After-Sales: 24/7 online support, with a 1-year warranty on all parts and components.
Customer Success & Testimonials
*”In conclusion, We replaced three old separate machines with one LiJian 503. Our floor space saved is remarkable, and output has increased by 30%. The precision is consistent.”*
— Production Manager, Switchgear Manufacturer, Germany
“Consequently, Their support team helped us customize several special punching molds. The machine handles our complex transformer busbar work perfectly.”
— Engineering Director, Transformer Company, Turkey
Frequently Asked Questions (FAQ)
Q1: How do I choose between the 300KN, 500KN, and 800KN models?
The primary factor is the maximum thickness and width of the busbars you process daily. Use our Model Comparison table above. For mixed batch production, choosing a model with slightly higher capacity than your current need is often a future-proof investment.
Q2: What is the meaning of R3, R5, R10, R80 in bending dies?
The “R” stands for the internal bend radius it produces (e.g., R5 creates a 5mm radius). Different radii are required by various electrical design standards to prevent insulation stress and corona effect.
Q3: Can the machine process aluminum busbars?
Yes. The machine is capable of processing both copper and aluminum busbars. However, due to aluminum’s different material properties, tooling wear and cutting/punching parameters may differ. Consult our engineers for specific aluminum applications.
Q4: What is the lead time and warranty?
Standard model lead time is 10-25 working days after order confirmation. We provide a comprehensive 1-year warranty covering parts and workmanship, with lifetime technical support.
Q5: Do you provide installation and training?
Yes. We provide detailed installation manuals, video guides, and online video conference training. Onsite installation and training services are available as an optional package.
Finally, Ready to transform your busbar production line? The LiJian® team is here to provide you with a tailored solution.
