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The fully automatic steel cage workstation is a piece of steel processing equipment that integrates intelligence, modularity, and high precision. It is widely used in fields such as bridges, subways, and building pile foundations. It replaces traditional manual binding and welding with automation technology, significantly improving production efficiency and product quality. The following is a detailed analysis of its core functions, performance, and product advantages:
Full-process automated production
Main bar and stirrup treatment: Supports automatic feeding, threading, and positioning, welding and fixation of main bars, as well as straightening, winding, and welding of stirrups. The entire process requires no manual intervention.
Welding automation: Equipped with CO₂ shielded welding machines or automatic welding manipulators, the welding speed can reach 40-60 points per minute, with full weld points and minimal loss.
High-precision control and flexible adaptation
Numerical control system: Controlled by a PLC and servo driver, the spacing error of the main bars is ≤1 cm, and the spacing error of the stirrups is ≤5 mm/m, ensuring uniformity in the cage body.
Multi-specification compatibility: It can process a wide range of pile diameters (400 mm to 2,500 mm), supports single/double main bar and stirrup combinations, and is suitable for various engineering requirements.
Modularization and rapid adjustment
Design of the material distribution tray and formwork: The formwork is replaceable, and the material distribution tray allows for quick adjustment of the number of main bars and the cage body diameter to meet the requirements of different engineering drawings.
Easy disassembly and assembly: The modular structure facilitates transportation and on-site installation, supporting both factory mass production and decentralized operations at construction sites.
Intelligent detection and fault-tolerant mechanism
Main bar detection: The system automatically detects the length of the main bar. When an abnormality occurs, it triggers an alarm and discards the material, reducing human error.
Safety protection: The system is equipped with a hydraulic support device (such as an 80-ton oil cylinder) to prevent the cage from sagging and deforming. A buzzer and limit sensor are also installed to prevent equipment damage.
1. Processing Efficiency
High production capacity: A single shift (3-6 workers) can produce 8-15 12-meter-long steel cages, with a daily output of over 20, making the efficiency four times that of manual labor.
Fast welding: The welding cycle for a single main bar is under 35 seconds, and welding a 9-12 meter cage body takes only 20-25 minutes.
2. Quality Stability
Mechanization standards: The main ribs are evenly distributed, the cage body diameter error is ≤1 cm, the weld point strength is high, and the pass rate for supervision and acceptance is nearly 100%.
Low material loss: The loss rate of CNC centralized processing is only 1.5%, reducing costs by approximately 10% compared to manual decentralized processing.
3. Energy Conservation and Environmental Protection
Energy consumption optimization: By adopting variable frequency motors and servo drive systems, the total power consumption is 10-24 kW, which saves 30% more energy compared to traditional equipment.
Green production: Closed factories reduce pollution, and CO₂ welding reduces smoke and dust emissions, meeting environmental protection standards.
4. Equipment Durability
High-strength materials: The flange is formed by cold-bending seamless steel pipes, and the key components are treated with shot blasting and painting, extending the service life by 50%.
1 Intelligent and User-friendly
Interface optimization: Touchscreen-guided parameter input (such as diameter, spacing, and welding time), supports data verification, and lowers the operational threshold.
Imported component guarantee: ABB and Panasonic electrical control systems are used, featuring high operational stability and a low failure rate.
2 Structural Design and Compatibility
Lightweight optimization: Improvements to the fixed/mobile frame structure reduce equipment weight and support the processing of heavy-duty cage bodies.
Multi-functional expansion: Optional modules, such as automatic feeding manipulators and double-rib synchronous welding, can be selected to meet complex engineering requirements.
3 Economy and Service Guarantee
Cost savings: Reduced reliance on labor. The processing cost per ton is approximately 240 yuan, which is 8% lower than manual processing.
After-sales support: We offer technical training, 24-hour maintenance response, and rapid spare parts replacement to ensure continuous production.
4 Engineering Adaptability
Ultra-long customization: Supports the production of cage bodies up to 23 meters long to meet the needs of special scenarios, such as subways and bridges.
Flexible site: The modular design is suitable for both centralized processing in factories and decentralized operations at construction sites, saving temporary land.
The fully automatic steel cage workstation achieves full-process automation and high-precision standardization of steel bar processing through intelligent control, modular design, and efficient welding technology. Its core functions cover every step, from raw material processing to finished product welding. Its performance is significantly superior in terms of efficiency, quality, and energy conservation. Additionally, structural optimization and after-sales service have further enhanced its market competitiveness. This equipment is not only a key tool for improving engineering efficiency but also a core device for driving the intelligent transformation of the construction industry.
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