LYGH2500 Cage Roller Welding Machine: Variable Pitch + Multi-Shape Adaptation Empowering Efficient Cage Production

he CM PRO 2500 Cage Roller Welding Machine is an intelligent core equipment specially designed for cage processing in large-scale infrastructure projects. It takes "variable pitch spiral winding + multi-shape cage compatibility" as its core competitiveness, and can process cylindrical cages with a maximum diameter of 2500mm. At the same time, it breaks through the single-shape limitation of traditional equipment and can directly produce square, rectangular cages and special-structured cages with 90° bends at the ends, bottleneck-type and pointed-type cages. Relying on the precise empowerment of the SAF 3000 fully automatic welding unit, the equipment realizes the full-process automation from main reinforcement positioning to spiral winding and welding forming. Currently, it has become a preferred processing equipment for bridge pile foundations, wind power foundations, large-scale utility tunnels and other projects, completely solving the pain points of traditional processing such as "low efficiency, single shape, and cumbersome pitch adjustment".

Core Configuration: SAF 3000 Welding Unit + Modular Structure Laying a Solid Foundation for Performance

• SAF 3000 Fully Automatic Welding Unit: As the "welding heart" of the equipment, this unit adopts twin-wire synchronous welding technology and is matched with an intermediate frequency inverter welding power supply. The welding speed of a single welding head reaches 1.2 times per second, which is 60% more efficient than traditional single-wire welding machines. It monitors current and voltage parameters in real time during welding. When wire deviation or current fluctuation occurs, the system can automatically adjust within 0.3 seconds to ensure uniform weld penetration - the penetration can reach 0.3 times the diameter of the steel bar, far exceeding the requirements of the *Code for Welding and Acceptance of Steel Bars*, and the pass rate of weld pull strength test is stably above 99.8%. The unit is equipped with an automatic slag cleaning device, which completes slag cleaning within 10 seconds after welding without manual secondary processing.

• Variable Pitch Spiral Winding System: Equipped with a spiral winding mechanism driven by a servo motor, the pitch parameters can be preset through the PLC numerical control system (supporting stepless adjustment within the range of 50-300mm). During the winding process, the spindle speed and the wire feeding speed of the stirrup are intelligently linked to ensure a pitch error of ≤±2mm. Aiming at the special pitch requirement of "dense at the bottom and uniform in the middle" in pile foundation engineering, the equipment can preset 3 different pitch parameters and complete variable-pitch winding with one key without stopping for adjustment in the middle, saving 40% of variable-pitch time compared with traditional equipment.

• Multi-Shape Compatible Structure Design: Breaking through the limitation of traditional cylindrical cage processing, the equipment is equipped with an adjustable main reinforcement positioning module - it can quickly adapt to the processing of Φ12-40mm main reinforcement by replacing positioning chucks of different specifications; when processing rectangular and square cages, it only needs to select the corresponding shape template on the touch screen, and the positioning module automatically adjusts the main reinforcement spacing (minimum spacing 100mm, maximum spacing 600mm) without replacing the core mold. For special cages with 90° bends at the ends, bottleneck-type or pointed-type, the equipment integrates an end forming mechanism, with a bending angle accuracy of ±1° and a bottleneck section diameter error of ≤±3mm, meeting the customized needs of wind power foundations and special pile foundations.

• Large-Diameter Stable Support System: Aiming at the processing of extra-large diameter cages with a maximum of Φ2500mm, the equipment adopts a support structure of "double rotating discs + middle supporting rollers" - the fixed rotating disc and movable rotating disc are integrally forged with quenched and tempered steel, with a load-bearing capacity of up to 5 tons; the middle supporting roller group can automatically adjust the spacing according to the cage length (stepless adaptation within the range of 2-20m), effectively avoiding the "eccentric shaking" problem when the large-diameter cage rotates and ensuring stable welding process.

Core Performance: Implementation of Three Major Advantages of High Efficiency + Flexibility + Stability

1. High-Efficiency Production: Single-Shift Output Increased by 3 Times Compared with Traditional Methods

2. Flexible Adaptation: Multi-Scenario Switching Without "Stopping for Mold Change"

3. Stable Quality: "Zero Rework" in Acceptance Reducing Late Costs

Adaptation Scenarios: Covering All Needs of Large-Scale Infrastructure

• Bridge and High-Speed Railway Infrastructure: Adapting to the processing of large-diameter pile foundation cages (Φ1500-2500mm) for cross-river bridges and high-speed railway super-large bridges, the variable pitch function meets the reinforcement densification requirements at different depths of pile foundations;

• Wind Power and New Energy Foundations: Producing bottleneck-type and pointed-type cages for wind turbine tower foundations, the Φ2500mm extra-large diameter adapts to the load-bearing needs of high-power wind power equipment;

• Municipal and Utility Tunnel Engineering: Processing rectangular and square cages (600×600mm-1500×1200mm) for urban comprehensive utility tunnels, adapting to the reinforcement processing needs of utility tunnel walls and top slabs;

• Special Engineering Fields: Used for customized cage processing in projects such as port terminals and deep foundation pit support, the 90° end bending function meets the connection needs between cages and embedded parts.

Operation and Maintenance: Easy to Learn Even for Novices

Core Technical Parameters