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I. Technological Breakthrough: From Mechanical Control to Intelligent Forming
Fully automatic busbar bending machines, core equipment for copper and aluminum busbar processing in power systems, are undergoing a revolutionary upgrade from traditional hydraulic drive to fully servo-controlled intelligent control. Shandong Gaoji's GJCNCBBAT series, for example, utilizes dual servo motors to drive ball screws, coupled with a closed-loop feedback system using a linear encoder, achieving a bending angle accuracy of ±0.2° and a positioning accuracy of ±0.5mm. The equipment utilizes proprietary CAD/CAM software, allowing direct import of 3D drawings to generate machining programs. A single 10mm thick copper busbar can be bent 90° in just 8 seconds, a 30% improvement in efficiency compared to traditional equipment.

Core technological innovations are reflected in three key areas:

Multi-axis linkage control: The Yonglian US-45E-8 integrates 3D bending and spring forming functions. Using multiple servo motors to independently control the bending path, it can process complex battery connectors with twisting angles, meeting the precision assembly requirements of new energy vehicle modules. Intelligent Process Optimization: Jinan Rongruida's equipment, equipped with AI algorithms, automatically identifies material thickness and hardness, dynamically adjusting bending pressure and speed. The measured bending angle error over 10 passes was ≤±0.5°, and the gap between the copper busbar and the cabinet assembly was less than 0.2mm, far exceeding industry standards.
Modular Design: Shandong Gaoji's intelligent production line enables unmanned punching, shearing, bending, and milling. Workpieces are transported via AGVs, and a single machine can process busbars with thicknesses ranging from 3 to 12mm, reducing changeover time to 15 minutes.
II. Application Scenario: Precision Adaptation in the New Energy Revolution
The new energy sector has become the fastest-growing market for fully automatic press brakes. With the widespread adoption of TOPCon battery technology, demand for copper busbar processing for photovoltaic inverters has surged, with orders for specialized equipment increasing by 32% annually. Yonglian Group's press brake, designed specifically for plastic-coated copper busbars, utilizes segmented mold optimization to ensure the plastic layer is intact and spring-back-free during the bending process. It has been mass-produced in CATL's energy storage system production lines. In the new energy vehicle sector, the global copper and aluminum busbar market is expected to reach 45 billion yuan in 2025, driving a 4.2-fold increase in purchases of press brakes with laser positioning capabilities over the past three years.

Power infrastructure remains the largest application market. Ultra-high voltage (UHV) grid construction is driving a 22% increase in the production capacity of 800mm wide press brakes. Smart grid transformation requires equipment with processing data traceability, leading to an increase in IoT module penetration from 34% in 2023 to 51%. Jinan Rongruida customized a press brake for a power equipment manufacturer. This machine uses an MES system to collect real-time pressure and angle data, enabling full product lifecycle traceability and helping the customer achieve ISO 9001 certification.

III. Market Landscape: Domestic Rise and International Competition
The Chinese market for fully automatic busbar bending machines is expected to exceed 3.5 billion yuan in 2025, with a compound annual growth rate of 12%, showing significant regional concentration. The Yangtze River Delta region holds a 45.6% market share, with Jiangsu companies demonstrating significant advantages in high-precision CNC systems, achieving an average product accuracy of ±0.02mm, 30% higher than the industry average. Shandong Gaoji, with its 70% domestic market share, has had its intelligent production line recognized as Shandong Province's first set of technological equipment. Its core equipment has been exported to over 20 countries, including Southeast Asia and the Middle East.

Foreign brands still dominate the high-end market. German manufacturer TRUMPF's press brakes boast a precision of ±0.02°, but the unit price is high, reaching 2.8 to 3.5 million yuan. They primarily serve high-end sectors such as aerospace. Local brands are seizing the mid-range market through differentiated strategies: Rongruida's equipment is only 60% of the price of foreign brands and offers 24-hour on-site service. Its market share exceeds 35% among high- and low-voltage distribution panel manufacturers. Policies are accelerating domestic substitution, with Jiangsu Province offering a 30% subsidy to companies purchasing high-end equipment, with a maximum of 500,000 yuan per unit. IV. User Value: From Efficiency Improvement to Quality Revolution
Production efficiency has significantly increased. Rongruida's press brakes have a single-shift capacity of 550 pieces, a 30% increase over traditional equipment. This has helped a distribution cabinet manufacturer save 8,000 yuan in monthly labor costs and successfully fulfill a peak season order of 1,000 units. Shandong Gaoji's intelligent production line is fully unmanned, with a single workpiece processing cycle of just one minute and noise levels below 60 decibels, significantly improving the workshop environment.

Quality stability has become a core competitive advantage. Jinan Rongruida's equipment operates 24 hours a day without trouble, with angular error controlled within ±0.5°, a 50% improvement over the industry average, directly reducing customer rework rates from 15% to 2%. The equipment's fully enclosed protective cover (IP54 protection), photoelectric interlocking device, and standardized anti-wear hydraulic oil replacement have reduced the incidence of mechanical injuries by 82%.
V. Future Trends: Parallel Integration of Intelligent and Green Manufacturing
The deep integration of AI will become a technological high ground. Siemens' next-generation control system automatically optimizes bending paths. Using machine learning to analyze historical data, it predicts mold wear cycles and reduces maintenance costs by 25%. The trend toward green manufacturing is evident, with the proportion of models with oil mist recovery efficiencies ≥98% expected to increase from 41% in 2023 to 68% in 2025. Shandong Lijian's DGWMX series, with its energy-saving hydraulic system, reduces energy consumption by 18% compared to traditional equipment.

Modular and shared manufacturing models are emerging. Regional shared machining centers account for 7.8% of equipment investment. Small and medium-sized manufacturers can use high-end press brakes through leasing, reducing fixed asset investment. In the future, with the application of 5G and digital twin technology, equipment will enable remote diagnosis and virtual commissioning. It is expected that the proportion of intelligent equipment will exceed 55% by 2025, driving the industry's transformation from "manufacturing" to "intelligent manufacturing services."

Conclusion
Fully automatic busbar bending machines, as the "heart" of power equipment manufacturing, are undergoing technological evolution that is closely aligned with market demand. From traditional hydraulic drive to full servo intelligent control, and from single bending functions to integrated 3D forming, the industry is undergoing a transformation from "tool" to "intelligent platform." Driven by the dual forces of the new energy revolution and digital transformation, equipment with high precision, high reliability, and high intelligence will become the core of corporate competitiveness. In the future, with the deep integration of AI and IoT technologies, fully automatic busbar bending machines are expected to further break through the limits of efficiency and precision, injecting new momentum into the upgrade of global power infrastructure.