1 Product Overview: What is Model 2200 Rebar Cage Roller Welding Machine?
Model 2200 rebar cage roller welding machine is a CNC automated rebar processing equipment specially designed for manufacturing rebar cage structures required in various construction foundation projects. Controlled by a PLC (Programmable Logic Controller) system, the equipment precisely regulates the forming and welding processes of rebar cages, realizing automation and standardization of rebar cage processing. The number "2200" in its name refers to the maximum diameter of rebar cages it can process, which is 2200 millimeters (2.2 meters). This specification covers the pile foundation needs of most bridges, buildings and other infrastructure projects.
As a revolutionary alternative to traditional manual binding of rebar cages, Model 2200 rebar cage roller welding machine plays a crucial role in the field of infrastructure construction. It solves the pain points of low efficiency, unstable quality and labor intensity in traditional methods through mechanical automation. Typically composed of core components such as coil holder, feeding rack, main machine and operation console, the equipment integrates mechanical, electrical, hydraulic and automation technologies, becoming an indispensable high-efficiency production tool in modern rebar processing plants.
In terms of industry applications, Model 2200 rebar cage roller welding machine has been widely used in expressways, high-speed railways, large bridges, urban construction and water conservancy projects. Especially in the rapidly developing infrastructure construction in recent years, the equipment has significantly improved the standardization level and production efficiency of rebar cage processing, providing strong guarantees for project quality and progress. Many well-known domestic engineering enterprises such as China Railway Group and China Railway Construction Corporation have adopted this equipment on a large scale to enhance the modernization level of rebar processing.
![Rebar Cage Roller Welding Machine]( "Rebar Cage Roller Welding Machine")
2 Technical Parameters: In-depth Understanding of Performance Characteristics of Model 2200 Rebar Cage Roller Welding Machine
The technical parameters of Model 2200 rebar cage roller welding machine reflect its professional performance in the field of rebar cage processing. The equipment can usually handle rebar cages with diameters ranging from 800mm to 2200mm, covering various needs from conventional to large-scale projects. In terms of length, there are slight differences among equipment from different manufacturers. Common standard lengths are 12m, 13.5m or 18m, and some equipment can be customized to longer sizes according to project needs.
Processing Capacity: In terms of main reinforcement processing, Model 2200 roller welding machine can handle main reinforcements with diameters of 12-40mm; for winding reinforcements (stirrups), the processing range is generally 5-16mm. The spacing of coiled reinforcements can be steplessly adjusted within the range of 50-400mm (or 50-500mm). This flexibility enables the equipment to meet different requirements of rebar cage structures in various projects.
Power System: The equipment usually adopts 380V/50Hz industrial power supply, with a rated power of 18-23kW. Most welding systems adopt CO₂ shielded welding process, which has high efficiency and stable weld quality, ensuring the firmness of rebar cage joints.
Control Precision: In terms of control precision, the main reinforcement spacing error can be controlled within 1cm, while the coiled reinforcement spacing error can reach the high-precision standard of no more than 5mm within one meter. Such precision ensures the consistency and compliance of rebar cage products, meeting the strict requirements of high-standard projects.
Parameter Category | Technical Index | Remarks |
|---|
Processing Range | Diameter 800-2200mm | Some models can be extended to a larger range |
Standard Length | 12m/13.5m/18m | Customizable according to needs |
Main Reinforcement Diameter | φ12-φ40mm | Can handle single or double main reinforcement structure |
Winding Reinforcement Diameter | φ5-φ16mm | - |
Coiled Reinforcement Spacing | 50-400/500mm | Stepless adjustment |
Power Supply Parameter | 380V/50Hz | Industrial power standard |
Equipment Power | 18-23kW | Slight differences among different manufacturers |
Welding Method | CO₂ Shielded Welding | - |
Control Method | PLC Programmable Control | Some high-end models are equipped with touch screen |
In addition to the above basic parameters, Model 2200 rebar cage roller welding machine also has unique features in structural design. The equipment usually adopts a traveling system with rack and pinion transmission. Compared with the traditional sprocket
chain transmission, this design has the advantages of high transmission precision, low noise, good stability and easy maintenance. The rotating disk is mostly controlled by a servo motor, which achieves higher rotation precision and more precise start-stop control, thereby extending the service life of the equipment.
The automation level of the equipment is also an important manifestation of its technical characteristics. Through the PLC control system, operators can preset multiple rebar cage specification parameters, and the equipment can automatically complete the entire processing process from straightening, length fixing to welding. Some high-end models are even equipped with automatic parameter storage function, which can store parameters of hundreds of specifications of rebar cages, greatly simplifying the production preparation process for repeated orders.
![Rebar Cage Roller Welding Machine]( "Rebar Cage Roller Welding Machine")
3 Core Advantages: Why is Model 2200 Rebar Cage Roller Welding Machine Highly Favored?
3.1 Significant Improvement in Production Efficiency
The most prominent advantage of Model 2200 rebar cage roller welding machine lies in its amazing production efficiency. Compared with the traditional manual production method, the equipment can increase the processing speed of rebar cages by 3-4 times. Specifically, under normal circumstances, 5 workers per shift for material preparation and roller welding work in two shifts (10 workers in total per day), and can process more than 30 finished rebar cages of 12 meters in length per day, including all processes such as material preparation, roller welding, stiffener installation, detection tube installation and guide pad installation. With the same number of workers, manual work can only process 3-4 similar rebar cages per day. This efficiency improvement means significant progress guarantee and time saving for large-scale projects with tight construction periods.
3.2 Stable and Reliable Processing Quality
Model 2200 rebar cage roller welding machine also performs excellently in quality control. Due to the adoption of CNC mechanical operation, the spacing between main reinforcements and winding reinforcements is uniform, the diameter of rebar cages remains consistent, and the product quality fully meets the specification requirements. In practical application, during manual rebar cage production, project supervisors had to inspect the processing site almost every day. After using mechanical processing, supervisors basically implement "exemption from inspection" for mechanically processed rebar cages. This quality stability mainly comes from the equipment's precise control system. The main reinforcement spacing error can be controlled within 1cm, and the coiled reinforcement spacing error within one meter can be controlled within 5mm. Such precision is difficult to achieve by manual operation.
3.3 Significant Reduction in Production Costs
From an economic perspective, Model 2200 rebar cage roller welding machine can reduce production costs in multiple links:
Material Saving: Stirrups are tensioned without lapping, saving 1-1.5% of materials compared with manual operation, directly reducing the cost of rebar materials.
Labor Cost Reduction: Mechanized processing reduces the dependence on skilled rebar workers. A standard shift only requires 5-6 workers to operate, compared with 10-16 workers needed for traditional manual binding, saving a lot of labor costs.
Auxiliary Cost Reduction: Since the main reinforcements of the rebar cages processed by the equipment are evenly distributed, the lap joint of multiple rebar cages is very convenient, which saves hoisting time and improves the efficiency of subsequent construction links.
3.4 Improvement in Operational Safety and Labor Intensity
Model 2200 rebar cage roller welding machine also significantly improves operational safety and reduces labor intensity. Traditional rebar cage processing requires workers to perform heavy manual binding and welding operations, which are labor-intensive and have certain safety risks. Automated equipment replaces manual operations with mechanical operations. Workers only need to operate the equipment and perform auxiliary work, which not only reduces labor intensity but also reduces the chance of direct participation in dangerous processes. In addition, the equipment is usually equipped with multiple safety protection devices, such as emergency stop buttons and safety shields, to further ensure the safety of operators.
![Rebar Cage Roller Welding Machine]( "Rebar Cage Roller Welding Machine")
4 Application Fields: Wide Applicability of Model 2200 Rebar Cage Roller Welding Machine
As a key equipment for modern rebar processing, Model 2200 rebar cage roller welding machine has an application range covering multiple infrastructure construction fields, becoming an indispensable engineering equipment for national development.
Transportation Infrastructure Construction: In the construction of expressways and high-speed railways, pile foundation engineering is the key to ensuring the stability and safety of the line. Model 2200 rebar cage roller welding machine can provide high-quality and standardized rebar cage products, ensuring the bearing capacity and durability of pile foundations. After introducing the rebar cage roller welding machine in the Hanzhong West Section Project of Shitian Expressway, the processing quality and efficiency were greatly improved, and the processing cost was also reduced. Similarly, in the construction of urban expressways, such as the Shanhai Road Construction Project of Yantai Urban Expressway, Model 2200 roller welding machine was also used for rebar cage processing.
Urban Construction and Water Conservancy Engineering: Model 2200 rebar cage roller welding machine also plays an important role in fields such as subway tunnels, industrial and civil buildings, and hydropower stations. For example, in the depot project of Section 3 of Fuzhou Metro Line 4, which has high requirements for standardization and mechanization and high-quality positioning for the processing and production of bored pile rebar cages, the adoption of rebar cage roller welding machine has achieved remarkable results in terms of progress, quality and economy.
Special Structure Requirements: It is worth mentioning that Model 2200 rebar cage roller welding machine has the ability to produce rebar cages with special structures such as double main reinforcements and double stirrups, which enables it to meet the specific needs of different types of projects. The equipment can also flexibly adjust the diameter and length of rebar cages according to engineering requirements, providing truly customized solutions.
In terms of geographical application scope, China's Model 2200 rebar cage roller welding machine not only meets domestic construction needs but also is exported to many countries and regions such as Russia, Kuwait, Saudi Arabia, Iraq and Ethiopia, supporting global infrastructure construction and demonstrating the technical level and strength of Made in China.
5 Purchasing Guide: How to Choose a Suitable Model 2200 Rebar Cage Roller Welding Machine
5.1 Key Considerations for Equipment Selection
When selecting Model 2200 rebar cage roller welding machine, multiple factors should be comprehensively considered to ensure that the equipment can meet specific project needs:
Matching of Processing Capacity: First, confirm whether the processing range of the equipment is appropriate according to the rebar cage specifications commonly used in the project. The key parameters to focus on include the diameter range, maximum length, main reinforcement diameter range, winding reinforcement diameter range and adjustable range of coiled reinforcement spacing of the rebar cage.
Power and Transmission System: The power system and transmission mode of the equipment directly affect its performance and service life. Priority should be given to models adopting rack and pinion transmission, because compared with sprocket chain transmission, this transmission mode has the advantages of high transmission precision, low noise, good stability and easy maintenance. At the same time, check whether the hydraulic system pressure (usually 8-10Mpa) and hydraulic cylinder specifications are sufficient to support the scheduled processing weight.
Control System and Automation Level: Investigate the control system configuration of the equipment. A high-quality Model 2200 rebar cage roller welding machine should adopt PLC programmable control and be equipped with a frequency converter to adjust the speed. Touch screen operation interface, parameter storage function and remote control capability are also important features to improve the usability and efficiency of the equipment.
Brand and Quality of Key Components: Understand the brand and quality of the key components of the equipment. Electrical components and mechanical parts of well-known brands usually mean higher reliability and longer service life. At the same time, ask whether the equipment provides quality assurance for main components. For example, some manufacturers provide a two-year warranty for the main reinforcement fixing cylinder.
5.2 Manufacturer Selection and Service Guarantee
When selecting a supplier of Model 2200 rebar cage roller welding machine, attention should not only be paid to the equipment price but also to the manufacturer's strength and service capabilities:
Manufacturer's Qualification and Experience: Priority should be given to manufacturers with rich industry experience and good reputation. For example, some enterprises established early with large scale usually have more mature technology and more complete quality management system. Understand whether the manufacturer has passed authoritative certifications at home and abroad such as ISO9001 quality management system certification and EU CE certification.
After-sales Service System: A complete after-sales service is an important guarantee for the long-term stable operation of the equipment. Choose manufacturers that provide comprehensive after-sales services, including 24-hour maintenance response, regular return visits and remote technical support. For example, companies such as Shandong Feihong have established an "8-level service guarantee system" covering the entire process from equipment delivery to after-sales maintenance.
Customer Cases and References: Ask the manufacturer to provide previous customer cases, especially project experience similar to your own project type. Manufacturers with cooperation experience with large engineering groups are usually more trustworthy. If possible, try to contact the manufacturer's existing customers to understand the actual use of the equipment.
Technical Update and Training: Understand whether the manufacturer provides operation training and continuous technical upgrading services. This is crucial to ensure that the equipment can give full play to its efficiency.
By comprehensively considering the above factors and combining with their own project needs and budgets, users can select the most suitable Model 2200 rebar cage roller welding machine, laying a solid foundation for the smooth implementation of project construction.
6 Conclusion
As an outstanding representative of modern rebar processing technology, Model 2200 rebar cage roller welding machine has developed into an indispensable high-efficiency production tool in the field of infrastructure construction. Through automated and intelligent production methods, it has completely changed the operation mode of traditional rebar cage processing and brought revolutionary improvements in production efficiency, product quality, cost control and safety guarantee. With the continuous development of China's infrastructure construction and the progress of construction technology worldwide, Model 2200 rebar cage roller welding machine will continue to be optimized and upgraded, providing strong support for the construction of more century-old quality projects. For enterprises engaged in bridge, tunnel, highway, railway and other construction foundation engineering construction, investing in Model 2200 rebar cage roller welding machine is not only a wise choice to improve production capacity but also a strategic measure to adapt to industry development trends and enhance market competitiveness.
