The full-automatic
rebar cage welding workstation is an intelligent equipment integrating mechanical design, automatic control, and welding technology, specifically developed for the large-scale production of rebar cages. In the construction of large-scale projects such as bridges, high-rise buildings, and nuclear power facilities, rebar cages serve as the core component of pile foundations. Their quality and processing efficiency directly affect the safety and progress of the entire project.
Traditional manual welding of rebar cages is plagued by problems such as high labor intensity, unstable welding quality, and poor specification consistency. Against this backdrop, the full-automatic rebar cage welding workstation has emerged, and with its characteristics of high efficiency, precision, and reliability, it is boosting the rebar processing industry.
![rebar cage welding workstation]( "rebar cage welding workstation")
Equipped with an automatic programming control system, the workstation realizes fully automated production of rebar cage forming processes, including main reinforcement feeding, stirrup straightening and winding, and welding of stirrups to main reinforcements. This significantly improves both the processing efficiency of rebar cages and the quality of finished products.
Rapid Production: Taking a rebar cage with a diameter of 1 meter and a length of 12 meters as an example, the workstation can complete one finished product in only 20-30 minutes.
Continuous Operation: Some models of the equipment have set a production record in high-speed railway construction, achieving a daily output of 75 sections of 9-meter cages (675 meters per day).
Labor Savings: Traditional manual production requires 8-10 workers, while the automatic workstation only needs 3-6 operators, resulting in a labor cost reduction of 30%-50%.
Uniform Spacing: Fully mechanized intelligent winding ensures uniform spacing between main reinforcements and winding reinforcements, as well as consistent diameter of rebar cages.
Stable Welding Quality: Adopting a CO₂ shielded welding machine, it produces less welding slag and achieves high welding quality; an optional automatic welding manipulator can reach a welding speed of 40-60 points per minute.
Intelligent Monitoring: The monitoring interface allows real-time inspection of actual welding quality. In case of errors, timely follow-up can be conducted to ensure product standardization and consistency.
Labor Cost Savings: Compared with traditional manual welding, it can reduce the number of workers by 3-5, significantly lowering labor costs.
Less Material Waste: Precise automatic control avoids material waste and improves the utilization rate of steel.
Low Maintenance Costs: Key components of the equipment are made of high-quality materials and treated with special processes, ensuring durability and reducing maintenance frequency and costs.
PLC and Touchscreen Control: Easy to operate with flexible parameter settings, supporting quick switching between rebar cages of different specifications.
Servo Motor Drive: Ensures the overall dimensions of the finished cages meet requirements.
Wide Parameter Range: Adapts to pile diameters ranging from Φ800mm to Φ2500mm, standard rebar cage lengths of 12 meters (customizable), main reinforcement diameters of Φ12mm to Φ40mm, and winding reinforcement diameters of Φ5mm to Φ16mm.
High-Strength Materials: The entire machine is made of thick cold-rolled steel, making the body more solid and durable.
Optimized Transmission System: Adopts sprocket and chain transmission for rotation, ensuring stable operation.
![rebar cage welding workstation]( "rebar cage welding workstation")
The standardized operation process of the full-automatic rebar cage welding workstation is as follows:
Main Reinforcement Feeding: Pre-cut, thread, and polish the main reinforcements, then hoist and place them on the main reinforcement storage rack.
Coiled Reinforcement Feeding: Hoist the coiled reinforcement onto the pay-off rack and prepare for traction.
Stiffener Installation: Workers place stiffeners on the main support shaft; the umbrella-shaped support of the shaft opens to fix the stiffeners.
Coiled Reinforcement Threading and Fixing: Pass the coiled reinforcement through the straightening mechanism and fix it to the main reinforcement by cross welding.
Welding and Forming: The equipment automatically performs initial welding, formal welding, and final welding to form a complete rebar cage.
Separation and Unloading: Separate the rebar cage from the equipment, unload the finished product, and use the automatic cage-moving trolley to transport the finished rebar cage to the designated location.
Equipment Reset: Prepare for the next production cycle.
The full-automatic rebar cage welding workstation is widely used in the following fields:
Transportation Engineering: Pile foundations for high-speed railways, highways, and bridges.
Urban Construction: Foundations of high-rise buildings and urban viaducts.
Energy Facilities: Construction of nuclear power plants and water conservancy projects.
Public Facilities: Airport construction and port terminals.
Flexible Production: Realize quick specification switching through the MES (Manufacturing Execution System), supporting continuous production of small-batch, multi-specification orders.
Data Monitoring: Built-in process parameter database automatically calls the optimal welding parameters, reducing reliance on operators.
Remote Management: Enable real-time monitoring of production progress and output summary, and achieve lean management through real-time data push.
Through technological innovations in automation and intelligence, the full-automatic rebar cage welding workstation solves many pain points in traditional rebar cage processing and achieves an optimal balance of quality, efficiency, and cost.
As the construction industry continues to raise requirements for project quality, construction progress, and work safety, this intelligent equipment is bound to become the mainstream choice in the future rebar processing field, providing solid equipment support for the construction of various large-scale projects.
