⤢ PORTFOLIO — SIMULATION
2D Wire Bending Machine Servo-Driven Wire & Rod Forming
Simulation of a servo-driven machine bending wire and rod into 2D shapes via step-sequence programming. Spring-back compensation, bend angle and feed control.
Servo Wire Bending Sequencer CODESYS Lenze i750 Lenze c520 Spring-back
WIRE-BEND / SEQ v1.0 | Wire Bending Sequencer Controller
● RUNNING
▸ BENDING HEAD
ANGLE0°
POS0mm
▸ STEP
CURRENT0
TOTAL6
▸ FEED
LEN0mm
▸ STATUS
STATEIDLE
▸ PARTS
COMPLETED0
▸ AXES
FEED OK
BEND OK
▸ RECIPE
MODEL:
SPEED 1.0 ×
SEQ: Wire Bending · Servo Step What Does It Do?
- ▸ Bends wire/rod material into 2D shapes via step-sequence
- ▸ Each step applies a defined feed length plus bend angle
- ▸ Spring-back compensation ensures real angle accuracy
- ▸ Up to 199 steps can be programmed in sequence
How Does It Work?
- ▸ Feed servo advances wire; bending head applies the angle
- ▸ Sequencer executes each step in order, in sync with PLC
- ▸ Spring-back table auto-corrects angle per material type
- ▸ Structured Text (ST) manages step transitions
Industrial Use Cases
- ⚙ Automotive cable & fastener production
- ⚙ Furniture spring & hanger system production
- ⚙ Medical device wire forming
- ⚙ Electrical panel cable bending lines
- ⚙ Steel staple & retainer part production
- ⚙ Manufacturing of reinforcing steel
- ⚙ Manufacturing of heating system pipes for white goods.
// Manual Bending vs. Servo-Driven Wire Bending
| Criterion | ❌ Manual / Mechanical | ✅ Servo-Driven |
|---|---|---|
| Angle accuracy | ±3° | ±0.1° |
| Shape repeatability | ±2 mm | ±0.05 mm |
| Program count | Fixed | Unlimited |
| Bend compensation | Manual | Auto spring-back |
| Step programming | None | Full sequence |
// Typical Application Parameters
| Parameter | Value | Unit / Note |
|---|---|---|
| Wire diameter | 1–16 | mm |
| Max bend angle | 180 | ° |
| Feed rate | 200 | mm/s |
| Bending head | 360° servo | |
| Max steps | 199 | steps |
| Software | CODESYS & Lenze | Sequencer |
| Servo | Lenze i750 | 2-axis |
| PLC Task Cycle | 1 | ms |
// Cycle Phases
IDLE
System in standby, program loaded
FEED
Feed servo advances wire to target length
BEND
Bending head applies angle with spring-back compensation
DWELL
Hold during bend, stress distribution
RETRACT
Bending head retracts, moves to next step