Following several years of rapid growth, my country's machine tool industry has made significant strides in both the main machine and functional component sectors. However, the development of the functional component sector has lagged behind that of the main machine sector, representing a weak link in the CNC machine tool industry; consequently, greater support for machine tool functional components is required. High speed, high precision, five-axis simultaneous control, and multi-tasking (compound) capabilities define the future direction of machine tool development. Functional components must evolve in alignment with these trends to meet the needs of machine tool manufacturers. A commitment to independent innovation and a drive for progress remain central to manufacturers' strategies; guided by this philosophy, China's CNC industry is poised to achieve greater global competitiveness.

Since the 1990s, rapid economic growth has led to a surge in demand for infrastructure—such as factory buildings, equipment, and transportation facilities—far outstripping the production capacity for various metal tubes. As the required shapes for these tubes became increasingly complex, the design and development of tube-bending machine systems were spurred into action. Traditional 2D tube-bending machines could no longer satisfy complex industrial requirements, leading to the maturation of 3D tube-bending technology. The application of Programmable Logic Controllers (PLCs) in control systems provided the technical foundation necessary for complex tube-bending operations. More recently, the rise of domestic industries such as air conditioning and automotive manufacturing has shifted the demand for tube-bending machines from a focus on quantity to a focus on quality. This shift has driven a technological leap, finally introducing CNC technology to the sector. The integration of CNC technology represents a revolution in the tube-bending industry, delivering substantial improvements in both bending speed and precision.

Given the diverse workpieces and processing requirements involved, CNC tube-bending machines primarily utilize three structural configurations:

① Direct use of a CNC system. This approach offers high programming flexibility, allowing programs to be tailored to specific bending requirements while avoiding mechanical interference; however, it places higher demands on the programming skills of personnel. It generally does not support the direct input of XYZ geometric coordinate data for the bend.

② A control configuration combining a Programmable Logic Controller (PLC), position/speed control units, a touchscreen, and AC servo drive units. This system integrates PLC ladder logic and SFC programming with position/speed control units and touchscreens. It allows for the direct input of pipe-bending data and supports the conversion of XYZ geometric coordinates into YBC processing data. It offers high hardware reliability and software that is easy to maintain and redevelop.

③ This approach utilizes industrial-grade computers, servo motion control cards, and AC servo units. The software is developed using visual programming languages like VC or VB, fully leveraging computer resources; this method is commonly used for complex machinery involving intricate motion processes and mechanical trajectories. In addition to the capabilities of the second method, it includes features for detecting mechanical interference. While hardware reliability is slightly lower than that of PLC-based systems, we employ a control scheme combining a PLC, position/speed control unit, touchscreen, and AC servo drive unit. The designed system supports both manual and automatic operation modes; the automatic mode offers options for step-by-step bending and continuous bending, facilitating the processing of diverse pipe types. Upper and lower die switching is used to handle pipe fittings with varying bending radii. For pipes with special processing requirements, we have designed linked operations, motion decomposition, and auxiliary actions to prevent mechanical interference and automate the bending process. Today, the experts at Huameng will focus on the design of control programs for pipe-bending machines based on Mitsubishi position/speed control units. For automation equipment requiring precise position and speed control, this solution utilizes hardware such as PLCs, position/speed units, and AC servo units, combined with software using ladder logic and SFC diagrams. It represents an excellent system solution when balancing cost-effectiveness and reliability.

Zhangjiagang Huameng Machinery Technology Co., Ltd. specializes in the manufacture of pipe-bending machines, including CNC, hydraulic, and fully automatic models. Adhering to the business philosophy of "Customer First, Integrity-Based," we sincerely welcome new and existing clients to visit us; our entire team is dedicated to providing you with comprehensive service.