| Name | Portable busbar machine(Combined type) – busbar bending cutting and punching machine |
| Number | DHY-200 |
| Function | punching |
| type | CH-70 |
| Maximum pressure of punching | 36 tons |
| Maximum thickness of punching | Copper:12mm, steel:10mm |
| Mould parameter | 3/8″(ф10.5mm2),1/2″(ф13.8mm2),5/8″(ф17.5mm2),3/4″(ф20.5mm2) |
| Weight | 37KG |
| Oversize(cm) | 27*39*16 |
| Type | CWC-200 |
| Function | shearing |
| Maximum pressure of shearing | 30 ton |
| Maximum thickness of shearing | Copper:12mm, steel:10mm |
| Maximum width of shearing | 200mm |
| weight | 26KG |
| Oversize(cm) | 33*44*20 |
| Type | CB-200A |
| function | Horizontal bend |
| Maximum pressure of bending | 30 ton |
| Maximum thickness of bending | Copper:12mm, steel:10mm |
| Maximum width of bending | 200mm |
| weight | 29KG |
| Oversize(cm) | 29*38*20 |
| Name | Electric pump |
| Maximum pressure | 70Mpa |
| minimum | 7 Mpa |
| power | 750W |
| rate | 50HZ/60Hz |
| Oil storage | 7L |
| High-Pressure flow | 0.9L/min |
| Low-Pressure flow | 5.0L/min |
| voltage | 220V |
| speed | 1400r/min |
| Oil type | Antiwear hydraulic oil |
| Oversize(cm) | 36*43*28 |
| weight | 24KG |
| whole dimension | 1200mmx1300mmx800mm |
| Total weight | 210KG |
1. Basic parameters of the equipment (familiarize yourself with the upper limit first, and overloading is strictly prohibited)
Model: DHY-200 three-in-one busbar processing machine (cutting/punching/flat bending)
·Power supply: single phase 220V/50Hz
·Rated oil pressure: 700kgf/cm² (safety valve protection, cannot be adjusted without permission)
·Cutting station: maximum processing copper/aluminum row 200×12mm, output 30T
·Punching station: maximum 200×12mm, output 35T; maximum distance from hole center to row edge 110mm
·Bending station: flat bending 0~90°, maximum 200×12mm
⚠Important red line: It is forbidden to process busbars, stainless steel, and iron materials that exceed specifications. It is easy to collapse the mold and damage the cylinder.
2. Cognition of the overall machine structure
1. Hydraulic pump station host: built-in motor, hydraulic oil tank, reversing valve, pressure gauge
2. Reversing operating handle: four gears [cutting | punching | bending row | oil return] (core operating components)
3. Three independent workstations
oUpper left: punching station (CH-70)
oUpper right: Cutting station (CWC-200)
oBottom: Flat bending station (CB-200A)
4. Foot switch: controls the advancement of the oil cylinder; release the foot pedal, the oil cylinder stops, and switches to the oil return gear to automatically return.
5. Mold tool box: punching convex and concave dies, bending dies, wrenches
3. Comprehensive inspection before starting up (required process)
1. Hydraulic oil inspection: Observe the oil level in the tank and keep it between the MAX/MIN scale; 46# anti-wear hydraulic oil is recommended, and it is prohibited to mix different brands of hydraulic oil. A new machine needs to be changed for the first time after 3 months of continuous use, and then every 6 months.
2. Oil circuit and sealing: Check the oil pipe joints for oil leakage, bulges, and cracks; if the joints are loose, tighten them in time.
3. Check the mold and bolts. Check whether the upper and lower punching dies, cutting blades, and bending mold fixing screws are tight; there is no chipping or deformation of the mold.
4. Electrical inspection: The power cord is not damaged and the grounding is reliable; after turning on the power, jog the motor to confirm that the motor rotates normally. Turn the opposite direction and swap the two live wires on the power cord.
5. Clean the workbench. Remove iron filings and copper filings, and apply a small amount of anti-rust lubricant to the sliding parts.
4. General operating principles
1. When working at one station, the reversing handle can only move to the corresponding gear. It is prohibited to supply oil to multiple stations at the same time!
2. Unified template for the operation process: Select the work station → install the mold → place the copper bar and position → turn the reversing handle to the corresponding function → step on the pedal to process → complete the processing → turn the handle back [oil return] → automatically return the oil cylinder → take out the workpiece
3. If abnormal noise, material jamming, or pressure surge are found during processing, release the pedal immediately, switch back to the oil position, and do not force pressure!
5. Step-by-step detailed operation tutorials for the three major stations
Station 1: Cutting (cutting) operation
1. Turn the reversing handle to the [cut off] position
2. Feed the copper bar flatly into the cutting knife holder, align the cutting mark line with the knife edge gap, and keep the copper bar close to the workbench without tilting;
3. Keep your hands away from the dangerous area of the knife edge and slowly press the foot switch; the blade moves downward to cut off the busbar;
4. When the cutting is completed, release the foot pedal, switch the handle to [Oil Return], and the blade is fully reset;
5. Take out the workpiece and check the cutout for burrs. ✅Tips: Do not step on thick copper bars (≥10mm) all at once, apply pressure intermittently to make the incision smoother. ❌Prohibited: bevel cutting of copper bars, superimposed shearing of two copper bars.
Station 2: Punching operation (most frequently used)
1. Replace the mold after power outage: select matching punch + concave mold according to the hole diameter. The upper and lower molds must be in sets, aligned concentrically, and lock the fixing bolts;
2. Turn on the power and turn the reversing handle to [Punching];
3. Mark the hole position on the copper bar, place the copper bar on the punching workbench, and align the marked point with the center of the punch; the limit stop can be used for batch positioning;
4. Remove your hands from under the punch, step on the foot pedal, and press the punch down to punch; release the foot pedal after penetrating the plate;
5. Switch the handle back to [Oil Return], lift the punch up, and remove the copper bar.
Common supporting molds: Φ7, Φ9, Φ10.5, Φ13.8, Φ17, Φ20.5mm ⚠Fault prevention: If the mold is not concentric, the punch will collapse directly; thin copper bars should not be kept under pressure for a long time to prevent the busbar from denting and deforming.
Station 3: Flat bending (bending row) operation
DHY-200 only supports flat bending (wide-side bending of copper bars) and cannot be forced to bend vertically.
1. Install the upper and lower bending molds and confirm that the mold gap matches the thickness of the copper bar;
2. Turn the reversing handle to [Curved Row];
3. Put the copper wire into the bending mold slot, and align the bending center point with the mold benchmark;
Key point: There is springback when the copper bar is bent! If you want a 90° finished product, you need to press 3° to 6° more, and fine-tune it on site according to the thickness of the copper strip.
1. Slowly step on the foot pedal, and the oil cylinder pushes the mold to bend; release the foot pedal when the desired angle is reached;
2. Switch the handle to [Oil Return], return the mold, and take out the copper bar to measure the angle. ✅Experience: Copper bars with a thickness of 10~12mm have greater rebound, so bend them in stages and do not crush them to death at once. ❌Strictly prohibited: processing multiple layers of copper bars at the same time at the bending station.
6. Standard shutdown process
1. Turn the reversing handle to the [Oil Return] position and allow all oil cylinders to fully return to their initial positions;
2. Turn off the power switch and unplug the power plug;
3. Clean the copper scraps from the three stations, wipe the mold clean, and apply a thin layer of anti-rust oil;
4. Check whether there is any oil leakage, and sort out the oil pipes and foot switches;
5. After long-term shutdown, the mold should be disassembled and stored properly, and covered with a dust cover.
7. Safety operating procedures (mandatory)
1. Operators must wear protective glasses and are prohibited from wearing loose gloves near the knife edge or punch;
2. It is strictly forbidden to extend your hands into the mold stroke range during processing;
3. It is prohibited to disassemble and assemble molds and fasten bolts while the equipment is in operation; the power must be cut off when replacing molds;
4. If the continuous working oil temperature exceeds 60°C, stop the machine and allow it to cool for 20 minutes before use;
5. Do not adjust the safety valve pressure of the hydraulic system at will. Overpressure will cause the fuselage to crack and the oil pipe to burst;
6. Lock the casters when moving the equipment, and keep the body level during processing to prevent shaking.
8. Common faults and quick troubleshooting
1. The pedal cylinder has no action
oCheck whether the reversing handle is in the right position; whether the power supply and motor are running; the oil level is insufficient and the oil suction filter is clogged.
2. Insufficient pressure and inability to process
o Hydraulic oil has deteriorated or lacks oil; air is entering the oil circuit; internal seals are worn; safety valves are loose.
3. Punching burrs are large and holes are deformed
oThe punch die is worn and the gap is too large; the copper bar is not leveled; the single pressurization speed is too fast.
4. Unstable bending angle and severe rebound
oThe copper bar material has inconsistent hardness; no springback amount is reserved; the mold is worn.
5. Oil leakage from oil pipe joints
oThe joints are loose; the sealing rings are aging. Replace the O-rings in time.
9. Daily maintenance cycle
·Daily before shift: check oil level, clean copper shavings, check molds and oil pipes
·Weekly: Add lubricating oil to each sliding part and tighten all station fixing bolts
·3 months: Change the hydraulic oil for the first time; change the oil and clean the oil tank every 6 months thereafter
·Every year: Comprehensive inspection of cylinder seals, pressure gauge accuracy, and motor insulation