Intelligent Reinforcement Cage Welding Workstation - A New Era of Efficient Digital-Intelligent Driven Production

The Intelligent Reinforcement Cage Welding Workstation launched by Shandong Zhongji Luyuan Machinery Co., Ltd. takes intelligent manufacturing as its core, deeply integrates numerical control technology with industrial Internet of Things (IIoT) systems, and builds a digital closed-loop for the entire reinforcement processing workflow. Through the seamless collaboration of eight intelligent modules (including sawing and feeding, threading and grinding, and linked welding), the equipment realizes unmanned operation from raw materials to finished products, providing the construction industry with a high-precision, replicable, and standardized solution.

Digital-Intelligent Core: Flexible Production and Precise Control

• Cloud-Based Parameter Storage: It has 7 built-in process data templates. With one-click switching, it can adapt to diverse specifications, including a diameter range of 800-2500mm, main reinforcement diameter of φ16-50mm, and spiral reinforcement diameter of φ5-12mm. The response time is ≤5 seconds, completely eliminating reliance on molds.

• Dynamic Error Compensation: The servo fixed-pitch structure, combined with the intelligent length-measuring function, achieves a main reinforcement positioning accuracy of ±0.2 degrees, a spiral reinforcement pitch error of ±2mm, and a cage connection error of ≤2mm, ensuring 100% of products pass engineering acceptance.

• Multi-Machine Collaborative Operation: The 6-axis robotic arm with dual welding torches supports full welding/quincunx welding modes, with a single-point welding time of ≤1 second. It also links with the spiral reinforcement straightening module (variable frequency pay-off speed: 0-50m/min), improving the collaborative efficiency of processes.

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Intelligent Efficiency: Cost Reduction and Quality Improvement Driven by Data

• Capacity Leap: The dual-station design (Model HBZNS-2500) enables simultaneous skeleton forming and cage winding-welding. The single-shift (9-hour) capacity can reach 20-24 sections of 12m standard cages, representing a 300% efficiency increase compared to traditional processes.

• Resource Optimization: The lap-free design of stirrups saves 1.5% of materials. The comprehensive processing cost is as low as 34.3 yuan/ton (vs. 161.3 yuan/ton for traditional equipment), resulting in an annual labor cost savings of over 1.29 million yuan.

• Safety Closed-Loop: The man-machine separation operation, combined with a hydraulic emergency stop system (pressure: 10MPa), avoids risks during welding and cage unloading. The equipment meets the IP54 protection standard, making it suitable for harsh environments with dust and humidity.

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Industry Empowerment: Standardized Output and Future Expansion