Heavy Duty Rebar Cage Welding Machine
Fully Automated Continuous Welding: Integrates automatic feeding, positioning, spiral winding, and unloading into a seamless unmanned workflow, ensuring stable production with minimal labor.
High-Speed Precision Manufacturing: Fast welding cycles with CNC-controlled positioning deliver consistent cage quality, reduced material waste, and reliable high-output performance.
Flexible CNC Configuration System: Supports multiple cage specifications with one-click program recall, enabling rapid diameter adjustment and accurate, repeatable production.
Heavy Duty Rebar Cage Welding Machine YGTZ2500-12
The Heavy Duty Rebar Cage Welding Machine YGTZ2500-12 is a fully automated welding workstation engineered for high-efficiency rebar cage production using advanced proprietary technology. It is extensively applied in metro systems, bridge construction, building projects, airports, highways, and foundation engineering.
The system combines automatic main bar feeding, bar detection and positioning, spiral winding welding, and cage unloading into a seamless workflow. Welding operations require no manual intervention. The machine achieves exceptional efficiency, completing a single main bar weld in under 35 seconds. Welding parameters can be preset and stored according to production requirements, minimizing labor input while significantly boosting overall productivity.
The system supports continuous high-speed welding. A 9–12 meter rebar cage framework can typically be completed in about 20 minutes, while spiral winding and welding are finished in approximately 25 minutes. Welding quality is stable and reliable, with precise control of welding time and welding position to eliminate false welds and reduce material consumption.
Multiple cage specification parameters can be preset in the system. Operators can directly recall stored programs and perform one-touch touchscreen operation. The production-line workflow is simple and intuitive, with a high level of automation that ensures finished products fully comply with industry standards.
In traditional manual cage fabrication, on-site supervision is frequently required to verify production quality. With the Heavy Duty Rebar Cage Welding Machine YGTZ2500-12, the entire process is automatically monitored. Welding operations are recorded and inspected in real time, with system feedback providing timely operational data to ensure consistent and reliable manufacturing quality.
Comparison Table
| Comparison Item | CNC Rebar Cage Making Machine | Traditional Cage Rolling Welder | Traditional Cage Rolling Welder |
Welding capability | Automatic main bar welding + automatic spiral welding | Spiral welding automatic, main bars welded manually | Automatic main bar welding + automatic spiral welding |
Welding method | CO₂ shielded automatic welding, reliable quality | Manual welding, inconsistent quality | CO₂ shielded automatic welding, reliable quality |
Cage diameter range | 790–2340 mm, no mold change required | 800–2200 mm, multiple molds required | 790–2340 mm, no mold change required |
Diameter adjustment | CNC automatic support ring adjustment | Manual mold replacement | CNC automatic adjustment |
Feeding method | CNC chain automatic feeding | Manual loading | CNC chain automatic feeding |
Spiral bar diameter | Ø6–16 mm supported | Ø6–16 mm | Ø6–16 mm supported |
Cage docking | Automatic measurement compensation, accurate docking | Manual correction required | Automatic compensation docking |
Main bar configuration | Single or double main bars supported | Single main bar only | Single or double main bars supported |
Spiral bar configuration | Single or double spiral supported | Single spiral only | Single or double spiral supported |
Horizontal dual main bar | Supported | Not supported | Supported |
Inner support ring adjustment | CNC automatic positioning, high precision | Manual adjustment | CNC automatic positioning |
Number of main bars | 4–128 supported | Mold-dependent | 4–128 supported |
Operators required | 1 person | 4–6 persons | 1 person |
Production capacity* | 10–12 cages per shift | 6–8 cages per shift | 20–24 cages per shift |
Main bar welding time* | 15 minutes per 12 m section | Manual, inconsistent | 15 minutes per 12 m section |
Spiral welding time* | 15 minutes per 12 m section | 20 minutes per section | 15 minutes synchronized |
*Example based on Ø1.6 m cage production.
Technical Parameters
| Item | Specification |
Model | YGTZ2500-12 |
Cage inner diameter | 800–2500 mm |
Cage length | 12 m |
Max cage weight | 6000 kg |
Spiral bar diameter | 5–14 mm |
Spiral pitch | 50–500 mm |
Main bar diameter | 16–50 mm |
Hydraulic pressure | 10 MPa |
Total rated power | 100 kW (including 8 welding machines) |
Machine dimensions | 36 m × 8 m × 3 m |
Head travel speed | 0–3 m/min |
Spiral carriage speed | 0–3 m/min |
Cage rotation speed | 0–10 rpm |
Machine weight | ≈38 tons |
Main bar welding cycles | 0–3 times |
Main bar single weld time | 0–2 s |
Spiral welding mode | Full weld / staggered weld / adjustable |
Spiral weld time per point | 0–1 s |
Spiral configuration | Single / double spiral |
Main bar configuration | Single / double main bar |
Power supply | 380V / 50 Hz |
Cage unloading | Automatic trolley translation |
Moving welding units | 2 sets |
Smart bar length memory | Standard |
Main bar feeding | Pneumatic automatic positioning |
Bar alignment | Servo positioning |
Alignment accuracy | 3 mm |
Single main bar welding cycle | 30–50 s |
Cage lifting supports | 6 sets |
Lifting system | Hydraulic control |
Oil pump pressure | 10 MPa |
Air pressure | 0.9 MPa |
Cage rotation accuracy | ±0.2° |
Cage support method | Hydraulic support |
Spiral pitch accuracy | ±2 mm |
Stored cage programs | 30 sets |
Operators required | 1–2 persons |
Spiral pay-off speed | 0–50 m/min, adjustable |
Spiral straightening | Dual-roller straightening |
Spiral load capacity | 6000 kg |
Mold ring support | Hydraulic support |
Inner support rings | 6 pcs |
Support ring spacing range | 1700–2000 mm |
Spacing adjustment | CNC programmable |
Major Components List
| Component | Model | Notes |
Main turntable servo motor | 7.5 kW | 1 set |
Fixed-length travel servo motor | 2.3 kW | 1 set |
Carriage drive motor | 4 kW | 1 set |
Drum rotation motor | 7.5 kW | 1 set |
Spiral feeding motor | 3 kW | 1 set |
Spiral straightening motor | 5.5 kW | 2 sets |
PLC controller | — | 1 set |
Touchscreen HMI | — | 1 set |
Gear reducer | — | — |
Pneumatic cylinder | — | — |
Welding machine | 500 type | 8 sets |
Frequency inverter | — | — |
Electrical components | — | Relays/contactors/sensors |
Three-phase motor | — | Induction motor |
