In the steel cage fabrication process, the sawing, threading, and upsetting (thickening) of main bars are key preparatory steps that determine the connection strength and assembly accuracy of the steel cage. Traditional decentralized processing (manual sawing + standalone threading machines + manual upsetting) not only results in fragmented procedures and low efficiency, but is also prone to inconsistent bar lengths and substandard thread quality due to human error-thereby affecting the overall quality of the steel cage.
As an integrated automated system, the steel cage sawing, threading, and upsetting production line realizes standardized and efficient main bar processing through continuous operation of the entire process-from sawing → upsetting → threading → grinding → sorting-and has become the core equipment in steel bar processing workshops for large-scale infrastructure projects.
Core Advantages of the Production Line: Breaking Through Traditional Processing Bottlenecks
Compared with conventional decentralized methods, the steel cage sawing, threading, and upsetting production line achieves multiple breakthroughs in quality improvement, efficiency enhancement, and cost reduction through process integration and automated control. Its key advantages include:
-
Full-process automation - efficiency increased by 5 to 8 times
The production line requires only 1–2 operators for monitoring and operation, and can process 800–1,200 main bars per day. Each process is connected by conveyor systems, eliminating manual transfer and significantly reducing idle time between steps. It is especially suitable for large-scale projects that demand high throughput and fast turnover.
-
Industry-leading processing precision - ensuring connection quality
All stages are precisely controlled by CNC systems, and the core accuracy indicators far exceed manual standards.
Sawing accuracy: Length error ≤±1mm; end-face perpendicularity ≤0.1mm/m, preventing misalignment during cage assembly due to inconsistent bar lengths.
Upsetting accuracy: The upset (thickened) section diameter is 1.2–1.5 times the original bar diameter (for example, a φ25mm rebar is upset to φ30–37.5mm). The upset length error is ≤±2mm, ensuring the threaded root strength is not lower than that of the base material.
Threading accuracy: The thread profile meets the requirements of the Technical Code for Mechanical Splicing of Steel Reinforcing Bars (JGJ107), with a thread pitch error ≤±0.05mm. Suitable for straight-thread sleeve connections, the joint tensile strength exceeds 1.1 times that of the base material.
-
Significant reduction in labor dependency and material waste - achieving notable cost savings
Labor cost reduction >60%: The production line does not require highly skilled operators. Ordinary workers can begin work after 2–3 days of training, solving the problems of "difficulty recruiting skilled labor" and "high wage costs" typical of traditional methods.
-
Integrated layout - saving space and management costs
Traditional decentralized processing requires separate sawing, upsetting, and threading areas, occupying 200–300 m². The integrated production line uses a modular layout, occupying only 80–150 m² (depending on production capacity), reducing space requirements by more than 50%. Centralized production also simplifies quality control and equipment management, minimizing workshop management complexity.
Composition and Core Technical Parameters of the Production Line
The steel cage sawing, threading, and upsetting production line typically consists of seven core modules:
Feeding mechanism,CNC sawing machine,Automatic upsetting machine,CNC threading machine,Thread grinding machine,Sorting and conveying mechanism,PLC master control system
Each module operates in coordination to achieve full-process automation. The following are the core technical parameters of mainstream medium-sized production lines on the market (compatible with main bars from φ12–φ40mm):
| Module Name | Core Parameters | Function Description |
|---|---|---|
| Feeding mechanism | Suitable bar diameter: φ12–φ40mm; single bar length: 6–18m | Uses chain/roller conveyor; automatically aligns rebar ends; supports feeding of 10–20 bars at once |
| CNC sawing machine | Sawing speed: 0.8–1.5 m/min; saw blade diameter: 400–500mm | Hydraulic clamping + high-speed sawing; supports continuous cutting; automatically collects material heads |
| Automatic upsetting machine | Suitable for φ12–φ40mm bars; working pressure: 30–50MPa | Uses hydraulic upsetting; upset length adjustable from 20–50mm; automatically detects upset quality |
| CNC threading machine | Threading speed: 15–25 threads/min; thread size: M16–M45 | Rolling-thread processing; automatic oil lubrication; automatic chamfering after threading |
| Thread grinding machine | Grinding speed: 1500–2000 rpm; covers entire thread section | Steel wire wheel automatically removes burrs to prevent hand injuries during sleeve installation |
| Sorting & conveying mechanism | Conveying speed: 0.5–1 m/s; 3–5 sorting stations | Automatically sorts bars by specification and length for convenient cage assembly |
| PLC master control system | Touchscreen operation; supports parameter storage, fault alarms, and production counting | Stores over 100 sets of parameters; one-click specification switching; automatic shutdown and fault display |
| Total power | 50–80 kW (including all module motors and hydraulic systems) | Requires 380V industrial power; recommended to use an independent voltage stabilizer |
| Production line size | Length: 18–25m × Width: 3–4m × Height: 2.5–3m | Reserve 5m of operating space at each end; floor load capacity ≥5 tons/m² |