Wire Cage Forming Machine
2.Operation Mode: Fully automatic servo-controlled operation
3.Bending Mode: Integrated forming and cutting system
4.Rebar Diameter Range: φ5–16 mm
5.Bending Shape: Square, rectangle, polygon, customized hoop shapes
6.Bending Precision: ±1 mm
7.Power Supply: 380V / 50Hz / 3-phase
8.Control System: Smart CNC control with touch display
9.Production Efficiency: 1800–2450 hoops/hour
10.Main Materials: High-rigidity steel machine frame
11.Application: Rebar stirrup and reinforcement fabrication
Product Description
Wire Cage Forming Machine – High-Efficiency CNC Reinforcement Solution
In modern construction and precast industries, achieving consistent structural integrity while minimizing labor costs remains a critical challenge. The Wire Cage Forming Machine from Shandong Zhongji Luyuan Machinery Co., Ltd. addresses this with enterprise-grade automation technology. Established in 2016 with a registered capital of RMB 50 million, our company delivers fully automatic servo-controlled equipment capable of processing φ5–16 mm rebar with exceptional ±1 mm precision.
This CNC support band bowing framework coordinating bolstering, rectifying, twisting, and cutting in one-time shaping operations. With generation productivity coming to 1800–2450 bands per hour and greatest twisting speed of 1100°/s, your office can handle up to 1 ton per hour with fair one administrator. Our Machine combines bar and wire preparing capabilities, viably supplanting two isolated machines whereas possessing as it were 4.4 m × 1.7 m of floor space.
Trusted by China Railroad Bunch, CRCC, CSCEC, and traded to about 100 nations, our hardware underpins high-speed railroads, atomic control ventures, and urban foundation requiring thorough auxiliary tolerances.
Why Choose Our CNC Reinforcement Processing System
Dual-Mode Processing Capability
You gain remarkable flexibility with our combined bar-and-wire system. The equipment handles thick φ14–φ16 mm bars and thin φ6–φ12 mm wires without additional machinery. One-key switching between modes eliminates costly equipment duplication and reduces your initial capital investment by up to 40%.
Your production team operates a single interface for diverse stirrup requirements. This versatility proves essential when project specifications change mid-production, allowing immediate adaptation without workflow interruption.
Superior Precision Engineering
Every hoop meets exact engineering specifications with ±0.5° angle accuracy and ±1 mm length tolerance. Our smart CNC control system with touch display stores unlimited parameter configurations, ensuring dimensional consistency across thousands of pieces.
The curve straightening method eliminates material memory effects that compromise structural performance. High-rigidity steel machine frames maintain alignment even during 24-hour continuous production cycles, delivering reliable results your quality inspectors will approve.
Intelligent Automation Reduces Labor
Single-operator functionality transforms your production economics. Where traditional methods require 3-4 workers per shift, our Wire Cage Forming Machine achieves 6–10 times manual efficiency with one person monitoring operations.
Automatic bar loading and integrated forming eliminate repetitive manual handling. Your workforce reallocates to value-added tasks while the system executes complex polygon and customized hoop shapes through programmed sequences. This dramatically reduces labor intensity and addresses skilled worker shortages.
Cost-Effectiveness at Scale
Small footprint design maximizes facility utilization. The main unit requires just 7.48 m² while the complete production line occupies 90 m² – significantly less than conventional setups. Lower equipment investment combines with reduced operating costs to deliver rapid ROI.
Material waste drops through precise cutting control and optimized feeding systems. The equipment supports single or double wire processing, minimizing scrap rates to less than 2% compared to 8-12% in manual operations.
Technical Specifications
| Parameter | Specification |
|---|---|
| Wire Processing Range | φ6–φ12 mm |
| Bar Processing Range | φ14–φ16 mm |
| Wire Straightening Method | Curve straightening |
| Bar Loading Method | Automatic |
| Maximum Hoop Diagonal Length | 1500 mm |
| Maximum Wire Feeding Speed | 100 m/min |
| Maximum Bar Feeding Speed | 70 m/min |
| Maximum Bending Speed | 1100°/s |
| Length Accuracy | ±1 mm |
| Angle Accuracy | ±1° |
| Equipment Power (Main Unit) | 38 KW |
| Equipment Power (Production Line) | 50 KW |
| Operating Personnel | 1 person |
| Production Efficiency | 1 ton/hour (1800–2450 hoops/hour) |
| Floor Area (Main Unit) | 4.4 m × 1.7 m |
| Floor Area (Production Line) | 20 m × 4.5 m |
| Power Supply | 380V / 50Hz / 3-phase |
| Control System | PLC intelligent control with touch screen |
Key Applications
Infrastructure and Transportation Projects
Your high-speed railway and highway projects demand consistent reinforcement quality at scale. Our system produces stirrups for bridge foundations, tunnel linings, and elevated structures where millimetric accuracy prevents structural failures. The equipment handles high-volume requirements for bored piles and diaphragm walls in urban subway construction.
Nuclear and Hydropower Engineering
Safety-critical applications require zero-defect manufacturing. The Wire Cage Forming Machine meets stringent tolerances for containment structures and turbine foundations. Automated parameter verification eliminates human error in these high-stakes environments.
Precast Concrete Manufacturing
Rebar processing and distribution centers benefit from rapid changeover capabilities. You produce varied stirrup configurations for beams, columns, and specialized components without lengthy setup procedures. Consistent cage geometry ensures perfect fit during precast assembly operations.
Frequently Asked Questions
Q: How does the machine switch between bar and wire processing modes?
A: The PLC control system features one-key mode switching accessible through the touch screen interface. Transition time takes less than 2 minutes, with automatic adjustment of feeding speed, bending force, and cutting parameters. No mechanical modifications are required, allowing your operator to respond immediately to changing production requirements.
Q: What shapes can the equipment produce beyond standard rectangles?
A: Our CNC system fabricates squares, polygons, customized stirrup shapes, mesh bars, and hooks. You program complex geometries through the touch interface, storing unlimited configurations for repeat production. The system handles special-shaped requirements for architectural features and non-standard structural elements.
Q: How does production efficiency compare with manual bending methods?
A: Automated processing delivers 6-10 times manual productivity. A skilled worker produces approximately 200-300 hoops per 8-hour shift manually, while our equipment completes 1800-2450 hoops per hour. This translates to processing 1 ton of material hourly versus 0.12-0.15 tons manually, dramatically accelerating project timelines.
Q: What maintenance procedures ensure continuous operation?
A: The robust design features low failure rates with straightforward maintenance protocols. Daily inspection covers hydraulic fluid levels and straightening roller alignment. Weekly lubrication of moving components and monthly electrical connection checks maintain optimal performance. Our professional after-sales team provides technical support to minimize downtime.
Q: Can the system handle epoxy-coated or corrosion-resistant rebar?
A: Yes, the curve straightening mechanism accommodates coated materials without damaging surface treatments. Adjustable feeding pressure protects specialized coatings while maintaining processing speed. This capability is essential for marine environments and chemical exposure applications requiring enhanced durability.
Q: How does the equipment ensure consistent angle accuracy across production runs?
A: Servo-controlled bending heads with closed-loop feedback systems monitor actual vs. programmed angles in real-time. The PLC automatically compensates for material spring-back characteristics based on stored data for different rebar grades. This intelligent adjustment maintains ±0.5° precision regardless of material variations or ambient temperature changes.
Why Shandong Zhongji Luyuan Machinery
We deliver comprehensive intelligent rebar processing solutions backed by extensive industry experience. Our partnerships with China's leading construction enterprises – including China Railway, CRCC, CSCEC, and CCCC – demonstrate proven reliability in demanding applications. Products exported to nearly 100 countries reflect our global market presence and technical competence.
Advanced manufacturing capabilities ensure every unit undergoes rigorous quality control. Our nationwide sales network and professional after-sales team provide rapid response when you need technical assistance. We focus on customer-centric service philosophy, delivering value-added support that maximizes your operational efficiency.
Contact Us
Ready to transform your reinforcement processing operations? Our technical team will assess your Wire Cage Forming Machine requirements and recommend optimal configurations for your production environment. Contact us at sales2@shandongluyuan.com to discuss how our solutions enhance your project outcomes.
