Equipment Positioning:
The Leap from "Decentralized Processing" to "Centralized Intelligent Manufacturing"
The steel cage workstation is an intelligent, integrated set of equipment covering the entire process of steel cage forming, including core procedures such as main reinforcement feeding, stirrup winding, welding and forming, and finished product demolding. It is specially designed for batch processing scenarios of steel cages used in bridge pile foundations, building foundations, and underground pipe galleries. Compared with the traditional decentralized mode of "manual binding + single-machine processing," it realizes integrated production of "raw material in – finished product out." It serves as a core configuration for modern steel bar processing and distribution centers and large-scale infrastructure projects.
Core Components:
Four Major Modules Building a Full-Process System
The steel cage workstation consists of four collaborative modules, each precisely connected to form a closed-loop production chain:
Main reinforcement treatment module
Equipped with a main bar feeding frame and fixed-length cutting mechanism, it can accommodate 10–20 main bars of Φ16–Φ50mm. Fixed-length cutting is achieved through a servo feeding system (length error ≤±2mm). The cut main bars are automatically conveyed to the positioning area of the forming module without manual transfer. Xuhui Intelligent has added a main rib straightening function to this module, with a straightness error of ≤1mm/m, ensuring accuracy in subsequent winding.
Forming and welding modules
As the workstation's core, it includes a rotating drive mechanism, a stirrup wire feeding system, and multiple welding heads:
Rotary drive: A variable-frequency motor drives the turntable to rotate at a constant speed (adjustable 0–10r/min). The main ribs rotate synchronously with the turntable. The circumferential positioning error is ≤±5mm.
Stirrup wire feeding: After the coil bars are straightened, they are conveyed by a servo wire feeding wheel. The pitch can be set precisely within 50–200mm, and the wire feeding speed is automatically matched to the turntable's rotation.
Welding system: Equipped with 2–4 high-frequency welding heads, with welding current adjustable from 50–150A. Spot welding is performed at the intersections of main ribs and stirrups. Welding head pressure ≥300N prevents false welding.
Auxiliary demolding module
Adopts a hydraulic ejection or side-flip demolding design. Once processing is complete, the positioning fixture releases automatically, and the finished product is smoothly transferred out of the forming area via the hydraulic device and onto the receiving platform. For large-diameter steel cages (≥2000mm), Xuhui Intelligent has designed a telescopic demolding mechanism to reduce the risk of product damage.
Intelligent control system
Equipped with a touch-screen numerical control system, it has over 200 built-in steel cage processing templates and supports automatic trajectory generation via CAD drawing import. It also features production data statistics, displaying capacity, pass rate, and welding current in real time, enabling efficient production management and quality traceability.
Work Process:
Six Steps to Fully Automatic Steel Cage Forming
Parameter preset: Input parameters such as diameter, length, number of main bars, and stirrup pitch into the control system, which automatically generates the optimal processing plan.
Main reinforcement feeding: Main reinforcements are placed on the feeding frame, cut to fixed length, and automatically inserted into the forming module's circular positioning fixture.
Stirrup winding: The turntable drives the main reinforcement to rotate, while the wire feeding system synchronously delivers the stirrups, winding them tightly at the set pitch.
Automatic welding: The welding heads move in sync with stirrup feeding, welding each intersection. Welding current stability is monitored in real time.
Finished product demolding: After processing, the turntable stops, the fixture releases, and the demolding mechanism removes the cage.
Continuous production: After removal, the equipment resets automatically and begins the next cycle, achieving uninterrupted production.
Core Advantages:
Reshaping Steel Cage Processing Efficiency and Quality
Efficiency doubled, costs reduced
A single workstation can produce 30–60 cages per day (Φ1200mm), 6–8 times higher than manual binding. It requires only 1–2 operators. Labor cost per cage section is reduced by 70%, while welding material loss is cut by 30%.
Stable precision, controllable quality
Main reinforcement spacing error ≤±5mm, stirrup pitch error ≤±10mm, and finished product verticality error ≤1°. These fully comply with the Code for Acceptance of Construction Quality of Concrete Structures (GB 50204-2015).
Flexible adaptation, convenient operation
Supports quick switching between specifications. Adjustment for diameters Φ600–3000mm takes no more than 30 minutes. The CNC system features a graphical interface, enabling new operators to master it in one day, lowering the skill threshold.