The steel cage roll welding machine is a specialized automated piece of equipment that integrates the positioning of main reinforcement bars, the winding of stirrups, and automatic welding through a numerical control system. It is mainly used for producing steel reinforcement cages required for cast-in-place concrete piles and other engineering projects.
Its core function is to accurately form the distributed main bars and stirrups according to design parameters, replacing the traditional rough manual binding and welding process. It has become a landmark piece of equipment for steel reinforcement processing in modern infrastructure construction.
According to the degree of automation, mainstream equipment can be divided into semi-automatic and fully automatic types. Among them, the fully automatic model integrates modules such as circular bar straightening and intelligent welding manipulators. It can complete the fabrication of steel cages ranging from 2 to 27 meters in length in a single operation. It also supports diverse requirements for pile diameters from 0.45 to 1.5 meters and a maximum main reinforcement diameter of 40 mm.
Working Principle and Core Structure
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Core Working Logic
The equipment adopts the process principle of "double spiral rotation + synchronous feeding," and the specific process can be divided into six steps:
Material preparation: After the main bars are cut and connected, they are placed on the storage rack, and the coiled bars are hoisted onto the wire feeding rack.
Main reinforcement fixation: The main bars are manually inserted into the circular holes of the fixed and movable rotating plates and clamped in position.
Stirrup pre-treatment: After the coiled bars are straightened by the straightening mechanism, their ends are welded to one of the main bars.
Rotational winding: The two discs rotate synchronously, while the movable disc simultaneously moves backward at a constant speed, causing the stirrups to wind spirally around the main bars.
Automatic welding: The welding robot operates synchronously with the winding process, performing precise spot welding using CO₂ gas shielded welding.
Finished product removal: After processing is completed, the movable disc resets, the clamping device is released, and the finished cage is unloaded using hydraulic supports.
During this process, the mechanical sensors can withstand the strong light and electromagnetic interference generated during welding. Combined with the PLC control system, they ensure high positioning accuracy, keeping the stirrup spacing error within the allowable range specified by standards.
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Key Component Systems
Mechanical structure system: Includes fixed and movable rotating discs (with feed mechanisms), distribution discs (eight sets to reduce rotational resistance), and hydraulic supports (five units to prevent cage deformation).
Electrical control system: Equipped with ABB frequency converters, imported PLCs, and touch screens, allowing real-time adjustment of parameters such as welding speed and stirrup spacing without stopping the machine.
Welding system: Features an automatic welding manipulator supporting CO₂ shielded welding. The wire extension length is controlled within ten times the wire diameter to ensure weld quality.
Auxiliary systems: Include the main reinforcement storage rack (split structure for easy transport), coil bar straightening mechanism, electric wrench, and other auxiliary equipment.
Industry Application Scenarios
This equipment is widely used in major infrastructure projects, including:
Bridge engineering: Fabrication of pile foundation reinforcement cages for large railway and highway bridges, such as 1.25-meter diameter piles used in the Laoguanhe Extra-large Bridge of the Menghua Railway.
Building construction: Production of reinforcement cages for pile foundations of high-rise buildings and large factories.
Underground engineering: Fabrication of support structures for subways and integrated utility tunnels.
Water conservancy projects: Production of reinforcement cages for reservoirs, dams, and embankment reinforcement.
Tunnel engineering: Formation of components such as tunnel arch frames and steel mesh panels.