The steel cage rolling welding machine is an automated steel bar processing device that integrates mechanical, electrical, and hydraulic systems. It is specially designed for forming steel cages used in bridges, tunnels, high-rise buildings, rail transit, and other projects. Its core function is to precisely control the entire process of longitudinal main bar positioning, circumferential stirrup winding, and welding formation through a numerical control system. This replaces the traditional manual binding and welding method, achieving standardized and efficient production of steel cages.
Core Structure and Working Principle
Key Structural Components
Drive system: Consists of a fixed rotary drive system and a mobile rotary drive system. It uses sprocket and chain transmission to ensure synchronous rotation of the two discs. The traveling part achieves high-precision movement through gear and rack meshing.
Rebar processing unit: Equipped with a main rebar material rack, stirrup layout frame, and stirrup straightening mechanism, ensuring rebar straightness through a multi-round horizontal and vertical combination design.
Support and fixing devices: Five sets of hydraulic support systems are designed based on the parallelogram principle to prevent deformation of the steel cage caused by its own weight. The main tendon fixator and conduit ensure the uniform distribution of the main tendons around the circumference.
Control system: Adopts an ABB frequency converter, imported PLC, and touch screen, supporting digital setting and real-time monitoring of welding parameters.
Working Process
Material loading preparation: After the main bars are cut and connected, they are placed on the storage rack. The stirrups are hoisted onto the wire laying rack and passed through the straightening mechanism.
Reinforcement fixation: The main bars are inserted into the double-coil conduits and clamped, and the ends of the stirrups are welded to the starting ends of the main bars.
Automatic forming: The two discs rotate synchronously, while the moving disc advances at a constant speed to wind the stirrups. The welding manipulator simultaneously performs CO₂ shielded welding.
Finished product unloading: After reaching the set length, the stirrups are cut, the double discs are separated, the hydraulic supports are lowered, and the steel cage is returned to its original position.
Daily Maintenance Specifications
Daily inspection: Check that the emergency stop button and circuit connections are functioning properly, and inspect for oil leaks and loose bolts.
Regular maintenance: Clean the dust inside the electrical cabinet and apply grease weekly. Tighten terminal blocks and check the oil level every one to two months.
Special protection: The hydraulic system must be strictly protected from water ingress. Ensure proper heat dissipation of the electrical components and avoid covering them.
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