The fully automatic steel cage welding workstation is an integrated intelligent equipment that integrates the whole process of "raw material processing - precision welding - intelligent detection - finished product output". It is specially designed for infrastructure scenarios such as bridge pile foundations, expressways, subway tunnels, and building construction. It can realize unmanned operation for steel cages with a diameter of Φ800-2500mm from steel bar preprocessing to forming and welding. Compared with the traditional decentralized processing mode, the workstation seamlessly connects multiple processes such as sawing, threading, polishing, welding and transfer through modular integrated design and PLC numerical control system management and control. It completely solves the industry pain points of low efficiency, unstable quality and large consumables consumption of manual welding. As a core equipment responding to the infrastructure industrialization transformation policy, it has been applied on a large scale in key projects such as China Railway 12th Bureau and Lianyungang-Suzhou Expressway.
![Cage making workstation]( "Cage making workstation")
Core Configuration Modules
The workstation adopts the structure of "five core modules + intelligent control system", and each unit operates synergistically to realize the whole-process automation. The key configuration advantages are as follows:
Automatic Feeding and Preprocessing Module: Equipped with a vibrating bed type raw material bin and a stepped feeding mechanism, it can automatically disperse, sort and feed main reinforcements with a diameter of Φ18-32mm; integrated with a sawing, threading and polishing unit, it completes fixed-length sawing (error ≤ ±1mm), rib peeling and threading (thread profile fullness ≥ 99.5%) and end polishing in a single feed, providing high-precision base materials for subsequent welding.
Intelligent Transfer and Positioning Module: Adopts a magnetic suction transfer platform, which supports simultaneous grabbing and precise feeding of 3 main reinforcements, with a positioning accuracy of ±3mm; equipped with a hydraulic support ring adjustment mechanism, it can be programmatically adapted to the inner diameter range of 1700-2000mm, and the specification can be switched without replacing the mold.
Multi-mode Welding Module: Core configuration includes 6 six-axis welding manipulators and CO₂ gas shielded welding system, supporting multiple welding modes such as full welding and quincunx welding, with a single-point welding time as low as 1 second; the welding of main reinforcements and stirrups is carried out simultaneously, and the welding time for a single section of 12-meter-long steel cage is only 40 minutes (20 minutes for main reinforcements + 20 minutes for stirrups).
Real-time Detection and Feedback Module: Built-in weld quality visual inspection system and steel bar size sensing device, which real-time monitors key indicators such as weld spot fullness and main reinforcement spacing, and automatically shuts down and alarms in case of abnormalities; the supporting data traceability function can record the welding parameters and inspection reports of each section of steel cage.
Numerical Control Central Control System: A 7-inch high-definition touch screen is equipped with an industrial-grade PLC, with built-in 20+ sets of standardized processing parameter templates, supporting guided parameter input (only key values such as cage diameter and number of main reinforcements need to be set); the hierarchical authority design distinguishes operation and management authorities to avoid wrong parameter modification.
Core Performance Advantages
1. High Efficiency and Labor Saving, Doubled Production Capacity and Reduced Costs
The traditional manual welding of a 12-meter steel cage requires 6 people to cooperate for 2 hours, and the missing welding rate is 15%; this workstation only needs 1 supervisor to realize continuous production, with a single-shift output of 10-12 sections and a maximum daily output of 20 sections (two-shift system), which is an efficiency increase of more than 100%. The application data of the Lianyungang-Suzhou Expressway project shows that after the workstation is put into operation, the labor cost is reduced by 60%, and the annual cost saving of a single section exceeds 120,000 yuan; the material utilization rate is increased by 1.5%, and large-scale projects save more than 10 tons of steel consumables annually.
2. Precise and Stable, Qualified Quality and No Rework
Through the dual control of numerical control system and mechanical positioning, the main reinforcement spacing error is controlled within ±2mm, the stirrup spacing accuracy is ±5mm, and the cage diameter error is ≤±3mm, which is far higher than the standard of Code for Welding of Steel Bars; the six-axis manipulator welding ensures uniform and full welds, and the welding qualification rate increases from 85% of manual welding to 99.8%, with no internal defects detected by ultrasonic flaw detection. In the application of China Railway 12th Bureau project, the spot check qualification rate by supervision reaches 100%, and the on-site docking and hoisting efficiency is increased by 30%.
3. Flexible Adaptation, Quick Switch Between Multiple Scenarios
The standard model supports the processing of cage diameter Φ800-2500mm and cage length ≤13.5m. The main reinforcement diameter is adapted to Φ18-40mm, and the stirrup diameter covers Φ8-16mm. It can flexibly switch between single/double main reinforcement and single/double stirrup structures; the specification adjustment only takes 2 hours to complete parameter setting and mechanism adaptation without replacing the core mold, adapting to the customized needs of different scenarios such as bridge pile foundations and subway utility tunnels.
4. Safe and Energy-saving, Convenient Operation and Maintenance, Long Service Life
Adopts fully enclosed welding cabin and man-machine separation operation design, equipped with emergency stop button, infrared protection and oil fume purification system, which completely avoids the risks of welding sparks and harmful gases; equipped with 85kW energy-saving power system, which reduces energy consumption by 28% compared with traditional decentralized equipment. Daily maintenance only requires regular inspection of oil pressure (10MPa) and air pump pressure (0.8-0.9MPa). The designed service life of the equipment is 8-10 years, and the operating rate is ≥95%.
Workflow Analysis
Raw Material Feeding: The main reinforcement and stirrup raw materials are automatically sorted through the vibrating bed type bin, and the feeding mechanism sorts them according to the preset specifications and sends them to the preprocessing unit;
Precision Preprocessing: The sawing module cuts the main reinforcement to a fixed length (error ≤ ±1mm), and completes threading and end polishing simultaneously to ensure the welding surface is clean and burr-free;
Framework Forming: The magnetic suction transfer platform accurately sends the main reinforcement to the welding station, the hydraulic support ring fixes the cage diameter, and the manipulator grabs the main reinforcement to complete the circumferential positioning;
Synchronous Welding: 6 welding manipulators are evenly distributed along the circumference of the cage to complete the welding of main reinforcements and reinforcing rings simultaneously; the stirrup mechanism conveys the stirrups synchronously and completes the spiral winding welding, and the weld spot quality is monitored in real time;
Finished Product Output: After welding, automatic air cooling is performed, the detection module rechecks the size and weld quality, qualified finished products are pushed to the hoisting area, and unqualified products trigger an alarm and record the defect location.
Core Technical Parameters
| Parameter Item | Index of GHZ25-12 Standard Model |
|---|
| Processing Cage Diameter Range | Φ800-2500mm |
| Processing Cage Length Range | ≤13.5m |
| Main Reinforcement Diameter/Quantity | Φ18-32mm; 8-24 pieces (customizable) |
| Stirrup Diameter/Spacing | Φ8-14mm; 70-300mm (adjustable) |
| Single Section Processing Efficiency | 40 minutes/section (12m length) |
| Positioning Accuracy | Main reinforcement spacing ±2mm; Stirrup spacing ±5mm |
| Total Power | 85kW |
| Overall Dimension (Length×Width×Height) | 18m×6m×3.8m |
Application Scenarios
Bridge Infrastructure: Processing of pile foundation steel cages for expressways and railway bridges, adapting to the needs of large-diameter (Φ2000-2500mm) cages, and seamlessly connecting with pile foundation construction equipment;
Municipal Engineering: Processing of steel cages for subway stations and urban utility tunnels, standardized output ensures construction consistency of multiple sections, and supports customization of special-shaped cages;
Building Construction: Processing of foundation steel cages for commercial housing and indemnificatory housing, mass production improves construction period guarantee capacity and reduces on-site processing land demand;
Prefabricated Component Factory: Large-scale production of steel cages for prefabricated piles, pipe piles and other components, cooperating with prefabrication production lines to improve component quality consistency.
