Multi-station busbar processing machine is important equipment in the power equipment manufacturing industry. It integrates punching, shearing, bending and other functional modules to realize automatic and efficient busbar processing. The equipment is suitable for mass processing of conductive materials such as copper bars and aluminum bars, and can meet the requirements of busbar dimensional accuracy and shape complexity for electrical equipment such as switch cabinets and transformers. Standard operation procedures directly affect processing quality and service life, while safety precautions are key to ensuring personal safety of operators. This article analyzes operation procedures and safety specifications, and explains the importance of precautions with practical cases.

I. Three Core Steps of Standardized Operation Procedures

1. Pre-Processing Preparation: Parameter Setting & Material Positioning

Operators shall input parameters such as punching spacing and bending angle on the control panel according to busbar material (copper/aluminum), thickness (2–12mm) and processing requirements.

- Example: For 10mm copper bar, set punching die clearance to 0.15mm to avoid burrs caused by excessive clearance.

- Use special fixtures for material positioning, align busbar edge with processing datum line, and control error within ±0.2mm.

2. Processing Monitoring: Dynamic Adjustment & Abnormal Handling

During operation, monitor the hydraulic system pressure gauge (normal range: 15–20MPa) and motor running sound.

- Stop immediately if pressure fluctuation exceeds 10% or abnormal noise occurs.

- Example: Abnormal pressure drop was found during bending, caused by aging and leakage of hydraulic oil pipe; timely replacement avoided die damage.

3. Post-Processing Maintenance: Cleaning & Component Inspection

- Daily: Clean residues with compressed air, especially punching die edges and bending grooves.

- Weekly: Lubricate transmission parts such as guide rails and lead screws.

- Quarterly: Test insulation resistance of electrical system (shall be ≥1MΩ).

II. Four Key Safety Precautions

1. Mandatory Use of Personal Protective Equipment

Operators must wear cut-resistant gloves, goggles and anti-smash safety shoes. Proper PPE effectively reduces more than 90% of mechanical injury risks.

2. Isolation Management of Hazardous Areas

The processing area shall be equipped with grating protection. The equipment shall emergency stop within 0.2 seconds when a person enters the dangerous area. Regular inspection of grating is essential.

3. Dual Protection for Electrical Safety

- Equipment grounding resistance ≤4Ω.

- Check leakage protection device before operation.

- Good grounding avoids electrical damage to the control cabinet.

4. Regular Emergency Drill

Organize emergency drills for fire, electric leakage and other scenarios quarterly. Ensure operators are familiar with fire extinguisher location (within 5 meters of equipment) and emergency stop operation.

Standard operation of multi-station busbar processing machine is the basis for improving production efficiency and the bottom line for ensuring personal safety. Enterprises are suggested to establish a management system of “Operation–Maintenance–Emergency” and improve equipment efficiency through standardized operation and regular assessment.