Automatic Steel Cage Welding Workstation: Solving Infrastructure Processing Pain Points and Reducing Costs with Intelligent Advantages
The inefficient traditional processing mode of "workers waiting for materials and multi-post collaboration" is completely subverted by the workstation. With the full-process automated design of vibrating bed automatic feeding, magnetic suction transfer positioning, and six-axis manipulator synchronous welding, only 1 supervisor is needed to realize continuous production. The single-shift output reaches 10-12 sections, and the maximum daily output is 20 sections (two-shift system), which is more than 100% higher than the traditional mode.
The cost optimization effect is particularly significant: after the deployment of the Lianyungang-Suzhou Expressway project, the labor cost was directly reduced by 60%, saving more than 120,000 yuan per section per year; intelligent nesting and precise processing increased the material utilization rate by 1.5%, and large-scale projects saved more than 10 tons of steel consumables annually. The investment payback period can be shortened to within 8 months.
Product Details
In infrastructure projects such as bridge pile foundations, expressway subgrades, and subway utility tunnels, steel cage processing has always faced the three major challenges of "low efficiency, large quality fluctuations, and high labor costs". Traditional decentralized processing requires 6 workers to cooperate for 2 hours to complete one 12-meter steel cage, with a missing welding rate as high as 15% and annual labor costs exceeding 500,000 yuan. The emergence of the fully automatic steel cage welding workstation has reconstructed the processing logic with an "integrated intelligent solution" and become the preferred equipment for key projects such as China Railway 12th Bureau and Lianyungang-Suzhou Expressway. Its four core advantages directly address industry pain points!
1. High Efficiency & Labor Saving: Doubled Production Capacity and 60% Cost Reduction
The inefficient traditional processing mode of "workers waiting for materials and multi-post collaboration" is completely subverted by the workstation. With the full-process automated design of vibrating bed automatic feeding, magnetic suction transfer positioning, and six-axis manipulator synchronous welding, only 1 supervisor is needed to realize continuous production. The single-shift output reaches 10-12 sections, and the maximum daily output is 20 sections (two-shift system), which is more than 100% higher than the traditional mode.
The cost optimization effect is particularly significant: after the deployment of the Lianyungang-Suzhou Expressway project, the labor cost was directly reduced by 60%, saving more than 120,000 yuan per section per year; intelligent nesting and precise processing increased the material utilization rate by 1.5%, and large-scale projects saved more than 10 tons of steel consumables annually. The investment payback period can be shortened to within 8 months.
2. Precision & Stability: 99.8% Qualification Rate for Zero Rework
As the core stress component of pile foundations, the precision of steel cages directly determines project safety. The workstation achieves "millimeter-level precision control" through dual control of PLC numerical control system and mechanical positioning: the main reinforcement spacing error is ≤±2mm, the stirrup spacing precision is ±5mm, and the cage diameter error is ≤±3mm, which is far higher than the standard of Code for Welding of Steel Bars.
Equipped with 6 six-axis welding manipulators and a CO₂ gas shielded welding system, the single-point welding takes only 1 second, and the weld is uniform and full without false welding. The built-in visual inspection system monitors the weld quality in real time and automatically shuts down and alarms in case of abnormalities. The welding qualification rate has jumped from 85% (manual welding) to 99.8%. In the application of China Railway 12th Bureau's bridge project, the supervision spot check qualification rate reached 100%, and the on-site docking and hoisting efficiency increased by 30%, completely eliminating rework losses.
3. Flexible Adaptability: Seamless Switching Between Multiple Scenarios, Time-saving Without Mold Replacement
In infrastructure projects, the specifications of steel cages are changeable. Traditional equipment requires half a day to change molds and adjust machines, which seriously affects the construction period. The workstation breaks this limitation with a modular design: the standard model can adapt to the processing of cage diameters from Φ1200-2500mm and cage lengths ≤13.5m, covering main reinforcement diameters of Φ18-32mm and stirrup diameters of Φ8-14mm, and can freely switch between single/double main reinforcement and single/double stirrup structures.
More importantly, specification adjustment only takes 2 hours to complete parameter setting and mechanism adaptation, without replacing the core mold. It can seamlessly adapt to large-diameter cages for bridge pile foundations, customized special-shaped cages for subway utility tunnels, and large-scale production in prefabricated component factories, meeting the differentiated needs of multi-section construction.
4. Safety & Energy Saving: Convenient Operation and Maintenance, 8-Year Service Life for Stable Support
Addressing the safety and environmental protection pain points of welding operations, the workstation adopts a fully enclosed welding cabin and man-machine separation design, equipped with emergency stop buttons, infrared protection and oil fume purification systems, which completely isolate welding sparks and harmful gases and meet the green construction requirements of construction sites. The 85kW energy-saving power system reduces energy consumption by 28% compared with traditional decentralized equipment, saving more than 30,000 yuan in electricity bills annually.
Operation and maintenance are more worry-free: daily maintenance only requires regular inspection of oil pressure (10MPa) and air pump pressure (0.8-0.9MPa). Core components (welding manipulators, PLC system) have a 2-year warranty. The designed service life of the equipment is 8-10 years, and the operating rate is stably above 95%, providing reliable support for long-term continuous construction.
Customer Testimonials
After the deployment of the 1st Section Project Department of Guanyun-Shuyang Section of Lianyungang-Suzhou Expressway, the daily output of steel cages increased from 5 sets to 12 sets, the pile foundation construction period was shortened by 35%, and it was awarded the "Intelligent Construction Demonstration Equipment". China Railway 12th Bureau's bridge project processes 18,000 meters of steel cages annually, saving a total of more than 1.5 million yuan in labor and consumable costs!
The fully automatic steel cage welding workstation is not just a processing equipment, but also the core engine for the infrastructure industry to transform from "labor-intensive" to "intelligent and efficient". Whether it is accelerating the construction period, improving quality, reducing costs or ensuring safety, it can be your reliable partner. Consult now to get a customized intelligent processing solution!
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