automatic cage welding machine
Operation Mode: Automatic / PLC Controlled System
Welding Method: Gas Shielded Arc Welding
Rebar Diameter Range: 6–40 mm (adjustable)
Cage Diameter Range: 500–2500 mm (optional configuration)
Cage Length Range: Up to 12 m (customizable)
Power Supply: 380V / 50Hz / 3-phase (customizable)
Control System: PLC + Touch Screen HMI
Production Efficiency: 1–3 cages per hour (varies by size)
Main Materials: Heavy-duty steel frame construction
Application: Pile foundation, bridge construction, and civil engineering projects
Product Description
Automatic Cage Welding Machine for High-Efficiency Rebar Processing
Modern infrastructure demands precision and efficiency in rebar cage fabrication. Shandong Zhongji Luyuan Machinery Co., Ltd., established in 2016 with a registered capital of RMB 50 million, delivers enterprise-grade solutions through its advanced automatic cage welding machine. This fully automated rebar cage welding workstation handles cage diameters from 500 to 2500 mm and produces cages up to 12 meters in length.
With PLC-controlled accuracy, the framework accomplishes generation proficiency of 1–3 cages per hour, decreasing labor prerequisites by up to 80% whereas keeping up millimeter-level exactness. The gear bolsters primary bar distances across of 18–40 mm and winding bars of 8–16 mm, making it perfect for heap establishments, bridge development, and respectful designing ventures over about 100 countries.
Why Choose Our Rebar Cage Welding Solution
Your development ventures require steady quality and quick generation cycles. Conventional manual welding makes bottlenecks, conflicting dispersing, and security dangers that delay basic timelines.
Our framework kills these challenges through synchronized turn and longitudinal development. The gas-shielded circular segment welding strategy guarantees profound entrance with negligible scatter. You'll see quick enhancements in basic astuteness and generation speed.
The heavy-duty steel outline development withstands 24/7 mechanical obligation cycles. Servo control frameworks keep up culminate concentricity all through the welding prepare. This implies each cage meets details without revamp or rejection.
Technical Specifications
| Parameter | Value | Remarks |
|---|---|---|
| Model | LYZD-GJL2500 | - |
| Cage Diameter Range | φ700–φ2500 mm | - |
| Maximum Cage Length | 12 m | Customizable |
| Main Bar Diameter | φ18–φ40 mm | - |
| Spiral Bar Diameter | φ8–φ16 mm | - |
| Main Bar Type | Single/Double | Customizable for double bars |
| Spiral Bar Type | Single/Double | - |
| Spiral Bar Spacing | ≤300 mm | Adjustable |
| Hydraulic Pressure | ≤16 MPa | - |
| Air Supply Pressure | ≤0.8 MPa | - |
| Total Power | 30 kW | Welding power: 100 kW |
| Operating Personnel | 1 person | - |
| Production Efficiency | 13 cages / 10 hours | 12 meters per section |
| Footprint | 30 m × 8.5 m | - |
| Power Supply | 380V / 50Hz / 3-phase | Customizable |
| Control System | PLC + Touch Screen HMI | - |
Core Performance Advantages
Productivity Enhancement
Your production capacity doubles with fully automatic operation. The system completes 13 twelve-meter cages in a standard 10-hour shift. Touch-screen CNC control provides intuitive operation that new operators master within hours.
Labor Cost Reduction
Only one operator manages the entire welding process. This represents a dramatic decrease from traditional methods requiring 4-6 workers. Your labor costs drop significantly while safety improves through reduced manual intervention.
Welding Quality Consistency
Top-mounted automatic welding delivers straighter and more stable connection points. The system prevents missing welds or false welding through continuous quality monitoring. Every cage maintains uniform standards that meet international specifications.
Operational Flexibility
Quick specification changes accommodate different project requirements. The modular structure design simplifies maintenance and reduces downtime. Servo control systems adjust spiral spacing with precision, ensuring dimensional accuracy across all production runs.
Durability and Reliability
Reinforced frame construction supports long-term heavy-duty operation. The low failure rate keeps your production schedules on track. Stable hydraulic and cooling systems perform reliably even in high-dust construction environments.
Industry Applications
High-Speed Rail and Bridge Projects
The automatic cage welding machine produces heavy-duty pile cages that withstand extreme vertical loads and seismic activity. Zero-defect weld spots ensure safety-critical performance for elevated spans and deep foundations.
Urban Subway and Tunnel Construction
Tight urban environments benefit from consistent diaphragm wall reinforcements and precast tunnel segments. The equipment enables rapid deployment while maintaining structural stability in complex soil conditions.
Precast Concrete Manufacturing
Large-scale industrial plants rely on high-volume output with identical specifications. Standardized concrete columns and pipes fit perfectly during site assembly, even in harsh climates where manual welding would fail.
Nuclear and Hydropower Infrastructure
Critical energy projects demand the highest welding standards. Our system meets rigorous quality requirements for load-bearing structures in nuclear containment and hydropower installations.
Quality Control Standards
We implement comprehensive inspection protocols to ensure your equipment performs flawlessly. Pitch accuracy testing verifies spiral reinforcement spacing deviates no more than ±2mm using laser measurement.
Weld penetration and shear strength undergo destructive testing. Every joint meets or exceeds the tensile strength of base rebar according to AWS D1.4/D1.4M standards.
Concentricity inspection ensures finished cages remain perfectly cylindrical without spiraling or warping. Electrical insulation and grounding tests prevent voltage fluctuations in PLC and welding transformers.
Fatigue testing runs machines under full load to monitor heat dissipation. This confirms long-term durability in demanding construction environments.
Trusted by Industry Leaders
Our equipment serves major infrastructure projects through partnerships with China Railway Group, China Railway Construction Corporation, China State Construction Engineering Corporation, China Communications Construction Company, and China Nuclear Industry Construction Corporation.
These relationships demonstrate our credibility and product reliability. The automatic cage welding machine supports national and international landmark projects across railway, highway, bridge, tunnel, and energy sectors.
Global Service Network
With exports to nearly 100 countries and regions including South Korea, Malaysia, Thailand, Kazakhstan, Israel, and South Africa, we understand diverse market requirements.
Our professional after-sales support team provides technical assistance and maintenance services worldwide. Fast response mechanisms minimize downtime and maximize your operational efficiency.
We deliver customized solutions that address specific regional standards and environmental conditions. This global experience ensures your investment performs reliably regardless of location.
FAQ
Q: What cage specifications can this machine produce?
A: The system handles cage diameters from 700mm to 2500mm and lengths up to 12 meters. Main bars range from φ18–φ40mm, with spiral bars from φ8–φ16mm. Spacing adjusts to ≤300mm for various project requirements.
Q: How many operators does the machine require?
A: Only one trained operator manages the entire welding process through the PLC touch screen interface. This reduces labor costs by up to 80% compared to manual methods.
Q: What is the typical production efficiency?
A: The machine produces 13 twelve-meter cages in a 10-hour shift. Actual output varies by cage size and complexity, ranging from 1–3 cages per hour depending on specifications.
Q: Does the equipment meet international safety standards?
A: Yes, our manufacturing adheres to ISO 9001 quality standards and CE certification for electrical safety. The equipment operates safely in industrial environments with proper grounding and insulation.
Q: What type of welding technology does the system use?
A: The machine employs gas-shielded arc welding for deep penetration and minimal spatter. This ensures consistent weld quality that meets structural engineering requirements for high-stress applications.
Q: Can the machine handle double main bars or spiral bars?
A: Yes, the system accommodates both single and double configurations for main bars and spiral bars. We customize the setup based on your specific project requirements during configuration.
Q: What footprint does the equipment require?
A: The standard installation occupies approximately 30 meters × 8.5 meters. The compact design maximizes production capacity while minimizing your facility space requirements.
Q: What after-sales support do you provide?
A: We offer comprehensive technical assistance through our nationwide and international service network. Our team provides installation guidance, operator training, maintenance support, and rapid response for technical issues.
Contact Us
Ready to transform your rebar cage production efficiency? Our technical team will help you select the optimal configuration for your specific automatic cage welding machine requirements.
Email us at sales2@shandongluyuan.com to discuss your application needs and receive a detailed quotation.
