Steel Cage Roller Welding Machine: Fully Automatic Intelligent Equipment Empowering Infrastructure Construction
Product Details
As a core equipment for the intelligent transformation of the infrastructure industry, the steel cage roller welding machine is tailor-made for steel cage processing in projects such as bridge pile foundations, high-speed rail foundations, and municipal utility tunnels. It realizes the full-process automation of main reinforcement positioning, stirrup winding, and automatic welding through an industrial-grade PLC numerical control system, completely replacing the traditional manual binding and welding mode. It solves the industry pain points of low efficiency, large quality fluctuations, and consumable waste in manual processing. Currently, it has been applied on a large scale in key projects such as the Shiyan-Tianshui Expressway and Lianyungang-Suzhou Expressway of China Railway 15th Bureau, and has become a standard equipment in intelligent steel bar processing plants.
Core Configuration: Modular Structure Ensures Stable Operation
The equipment adopts a modular design of "intelligent control + precise execution + efficient welding", and each unit operates synergistically to realize full closed-loop control of processing. The key configuration highlights are as follows:
Core Performance Advantages: More Competitive in Cost Reduction and Efficiency Enhancement
1. Doubled Efficiency: Direct 60% Reduction in Labor Costs
The traditional manual processing of a 12-meter-long steel cage requires 6-8 people to cooperate for 4 hours. However, the fully automatic steel cage roller welding machine only needs 1 operator for monitoring. It can process 12-15 sections per single shift (8 hours), and the maximum daily output can reach 30 sections (two-shift system), with an efficiency increase of more than 300%. Data from the Shiyan-Tianshui Expressway project of China Railway 15th Bureau shows that after the equipment was put into use, the steel cage processing team was reduced from 12 people to 3 people, saving more than 600,000 yuan in labor costs annually.
2. Excellent Quality: "Zero Rework" in Supervision Sampling Inspection
Through the dual control of the numerical control system and mechanical positioning, the main reinforcement spacing error is ≤±2mm, the stirrup spacing accuracy is ±5mm, and the cage diameter consistency error is ≤±3mm, which is far higher than the requirements of the Code for Construction Quality Acceptance of Concrete Structure Engineering. The welding link adopts multi-welding head synchronous operation, the weld fullness reaches 99.5%, and there are no internal defects in ultrasonic flaw detection. The qualification rate is stably above 99.8%. After application in the Shiyan-Tianshui Expressway project, the supervision unit realized "exemption from inspection" for mechanically processed steel cages, and the on-site hoisting and docking efficiency increased by 35%.
3. Energy and Material Saving: 15% Reduction in Comprehensive Costs
The equipment is equipped with an intelligent nesting algorithm, which can optimize the main reinforcement blanking plan according to the processing list. Combined with the stirrup non-lap welding technology, the material utilization rate is increased by 1.5%-2%, and large-scale projects can save more than 15 tons of steel consumables annually. In terms of energy consumption, the intermediate frequency inverter welding power supply is adopted, which reduces energy consumption by 25% compared with traditional welding machines, and a single equipment can save more than 20,000 yuan in electricity bills annually.
4. Flexible Adaptability: Quick Switch Between Multiple Scenarios
The standard model supports the processing of cage diameters from Φ600-2500mm and cage lengths from 2-27m. It can adapt to main reinforcements of Φ12-40mm and stirrups of Φ6-16mm, and is compatible with various materials such as plain round steel and deformed steel. There is no need to replace the core mold when switching specifications; only parameter adjustment on the touch screen is required, and the transition from bridge pile foundation cage to municipal utility tunnel cage can be completed in 20 minutes. The modular design is convenient for trans-project transportation, and the disassembly and assembly cycle only takes 3-5 days.
Core Technical Parameters
| Parameter Item | Standard Model Index | High-end Customized Model Index |
|---|---|---|
| Processing Cage Diameter Range | Φ600-2000mm | Φ800-2500mm |
| Processing Cage Length Range | 2-18m | 2-27m |
| Main Reinforcement Specification | Φ12-32mm | Φ16-40mm |
| Single Section Processing Efficiency | 30-40 minutes/section (12m) | 20-30 minutes/section (12m) |
| Stirrup Spacing Accuracy | ±5mm | ±3mm |
| Total Power | 30-45kW | 45-60kW |
Application Scenarios and After-sales Service
The equipment is widely applicable to various infrastructure scenarios: bridge pile foundation steel cage processing (such as expressways, railway bridges), municipal engineering (subway stations, urban utility tunnels), housing construction foundation construction, large-scale production in prefabricated component factories, etc. According to the needs of different scenarios, customized solutions can be provided, such as ultra-long cage processing models and special-shaped cage welding modules.
The after-sales service system is complete: free on-site installation and commissioning, 3-person/2-day special training are provided; the whole machine has a 1-year warranty, and core components (PLC system, servo motor, welding torch) have a 2-year warranty; 24-hour technical hotline response, and 32 service outlets across the country realize on-site maintenance within 48 hours, ensuring the equipment operation rate ≥95%.
Leave your messages
