Automated R-Clip Forming Machine Design

I need a complete mechanical and control-system design for an automated R-clip forming machine that can take wire between 0.5 mm and 2.0 mm in diameter, feed it, cut it to length, and bend it into several preset R-clip sizes at the push of a button. The concept should assume continuous coil feed: the operator loads a wire spool, the rest—straightening, feeding, cutting, forming, and part ejection—happens automatically.

My priorities are reliability, repeatable accuracy across the size presets, and ease of maintenance; changeovers between sizes should be tool-free or require only quick-change tooling. If you have experience with cam-driven benders, servo-based CNC wire forming, or hybrid approaches, let me know which architecture you would adopt and why.

Please include in your proposal:

• 3D CAD assemblies and detailed part drawings suitable for fabrication
• Motion/control schematic (PLC or dedicated motion controller) with suggested sensor and actuator list
• Bill of materials with manufacturer part numbers and estimated costs
• Cycle-time estimate for the smallest and largest clip sizes
• A brief note on safety guarding and CE/UL considerations if relevant

I will review concepts based on mechanical soundness, projected throughput, and clarity of documentation.

Also, we'll provide the video of that machine for example purpose.