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Full-Automatic Steel Cage Welding Station: Intelligent and Efficient Empowerment for Large-Scale Infrastructure Steel Processing

Integrates full-chain functions such as steel straightening, feeding, positioning, welding, cutting, and collection to realize an unmanned operation process. Traditional manual processing of a 12m steel cage requires more than 10 people to cooperate, with a single-shift output of only 1-2 sections; the station only needs 3-5 auxiliary operators, the single-shift output is increased by more than 50%, and some models can complete the processing of a 12m standard section in 2 hours, shortening the construction period by more than 35%. After application in the Liansu Expressway project, the cumulative cost saving reached 120,000 yuan, and the personnel input was halved.

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Product Details

The full-automatic steel cage welding station is a core equipment for the digital transformation of large-scale infrastructure projects. It integrates full-process automated functions including automatic main reinforcement feeding, intelligent positioning, precise welding, and finished product collection, completely solving industry pain points such as low efficiency, unstable quality, and high labor intensity of traditional manual welding. Relying on flexible production technology and intelligent decision-making system, the station can adapt to the processing needs of steel cages of different specifications, and is widely used in bridges, expressways, municipal utility tunnels, prefabricated buildings and other fields. It achieves the industrial upgrading goal of "mechanization replacing manpower, automation reducing manpower, and intelligence achieving unmanned operation", and has become a standard equipment in modern steel processing and distribution centers.

rebar Cage welding Workstation

Core Advantages: Reconstructing the Efficiency and Quality Standards of Steel Cage Processing

Compared with traditional processing modes, the full-automatic steel cage welding station achieves multi-dimensional breakthroughs through technological innovation, with significant core advantages:

Full-Process Automation for Significant Cost Reduction and Efficiency Improvement: Integrates full-chain functions such as steel straightening, feeding, positioning, welding, cutting, and collection to realize an unmanned operation process. Traditional manual processing of a 12m steel cage requires more than 10 people to cooperate, with a single-shift output of only 1-2 sections; the station only needs 3-5 auxiliary operators, the single-shift output is increased by more than 50%, and some models can complete the processing of a 12m standard section in 2 hours, shortening the construction period by more than 35%. After application in the Liansu Expressway project, the cumulative cost saving reached 120,000 yuan, and the personnel input was halved.
Millimeter-Level Processing Precision with Stable and Controllable Quality: Equipped with high-precision laser sensors and servo closed-loop control system, it automatically calibrates the main reinforcement position and stirrup spacing, achieving millimeter-level welding precision with a mesh diagonal error of ≤2mm. Adopting optimized square welding electrodes and multi-transformer welding system, the weld penetration is uniform, the pass rate of tensile strength test exceeds 99.8%, and the electrode service life can reach more than 300,000 times, completely eliminating the problems of missing welding and insufficient welding in manual welding.
Flexible Production Adaptation for Seamless Switching Between Multiple Specifications: Supports the processing of cylindrical, square, and rectangular steel cages with a diameter range of 1.2-2.5m, compatible with main reinforcements of different specifications from Φ12-40mm, and can realize mixed processing of 5 steel bar diameters in the same mesh. Through the digital central system, it supports CAD drawing recognition and parameterized setting. Changing processing specifications does not require manual mold adjustment, and seamless switching can be completed within 30 minutes, adapting to the diverse needs of different engineering projects.
Energy Conservation, Environmental Protection and Low Consumption with Controllable Operation and Maintenance Costs: Adopts intermediate frequency inverter welding power supply, optimizing the installed power to 650kVA, and the power consumption is reduced by 50% compared with traditional equipment. Equipped with automatic slag cleaning device and intelligent fault diagnosis system, it can remotely monitor the equipment operation status and early warn of fault risks. Daily maintenance only requires regular inspection of electrode wear and welding wire remaining, and the core components have a long warranty period of 2 years, greatly reducing operation and maintenance costs.

Core Technical Configuration: Intelligent-Driven Processing Innovation

The excellent performance of the station stems from the integrated innovation of core technologies, and the key configurations include three major systems:

1. Intelligent Control System

Equipped with an industrial-grade touch screen and digital decision-making center, built-in more than 80 sets of common processing parameter templates, new operators can work independently after 2 hours of training. It supports parameterized setting and automatic generation of processing plans by importing drawings, real-time collection of processing data and formation of production reports, providing data support for refined management. Some high-end models are equipped with remote fault diagnosis function to realize off-site operation and maintenance guidance and ensure continuous operation of the equipment.

2. High-Efficiency Welding System

Adopts twin-wire synchronous welding or multi-transformer welding technology, with a welding speed of up to 1.2 times per second. For heavy-duty welding scenarios of large wall steel cages, it can complete the welding of the maximum specification cage of 6m×3.4m in 2 minutes. Equipped with automatic slag cleaning and water cooling system, it ensures stable and continuous welding process and adapts to the demand of 24-hour uninterrupted production.

3. Precision Feeding and Positioning System

Adopts a plate-type mobile feeding mechanism and directional paddle design to realize orderly feeding of steel bars one by one, increasing the feeding speed by 80%. Through laser positioning and intelligent deviation correction technology, it automatically corrects the steel bar placement deviation, ensures the cross positioning precision of main reinforcement and stirrup, and provides a solid foundation for high-quality welding. For the processing of large-diameter cages, it is equipped with a double rotating disc + middle supporting roller support structure to avoid eccentric shaking during rotation.

Wide Application Scenarios: Covering All Types of Infrastructure Projects

With strong adaptability and stable performance, the full-automatic steel cage welding station has been deeply applied in various large-scale infrastructure scenarios:

Transportation Infrastructure Field: Suitable for the processing of bridge pile foundations and tunnel lining steel cages in expressways and high-speed railways, such as the Xinyi River Extra Large Bridge and cross-river bridge projects of Liansu Expressway, ensuring the construction quality and progress of pile foundations;
Municipal and Utility Tunnel Engineering: Used for the processing of steel cages in urban comprehensive utility tunnels and urban rail transit, supporting the production of special-shaped cages such as rectangles and squares, and meeting the reinforcement needs of utility tunnel walls and top slabs;
Prefabricated Building Field: For the processing of steel cages of prefabricated walls, beams and columns, it has created the technologies of "precise insertion of internal and external stirrups" and "double-layer synchronous welding", improving the integrity and stability of components and assisting the industrialized production of prefabricated buildings;
Special Engineering Scenarios: Suitable for the customized processing of steel cages in projects such as ports and terminals, airport runways, nuclear power and hydropower, and can realize the integrated forming of special structures such as 90° end bends and bottleneck types.

Standardized Processing Process and Operation and Maintenance Specifications

1. Processing Process

Raw Material Preparation: Feed coiled steel bars or straight steel bars into the feeding area, and the equipment automatically completes straightening and fixed-length cutting;
Parameter Setting: Import processing drawings or select preset templates through the touch screen, and set parameters such as cage diameter, length, and spacing;
Automatic Processing: The equipment sequentially completes main reinforcement positioning, stirrup winding, and multi-point synchronous welding, and real-time monitors the welding quality during the process;
Finished Product Output: After welding, automatic cutting and separation are completed, the finished products are transported to the storage area by the conveyor belt, and processing data reports are generated simultaneously.

2. Operation and Maintenance Specifications

Daily maintenance requires three core tasks: check the welding electrode wear and welding wire remaining every day, and replace worn parts in time; clean the welding slag and debris inside the equipment every week, and check the water level and water quality of the cooling system; inspect the lubrication of servo motors and reducers every month, and calibrate the positioning precision. When the equipment malfunctions, early warning information can be obtained through the intelligent diagnosis system, and professional teams can be contacted for on-site maintenance within 48 hours.

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