Equipment Overview
The Fully Automatic Rebar Cage Forming Machine YGTZ2500-12 is a rebar cage production system independently developed by our company with proprietary intellectual property rights. It is mainly used in metro construction, bridges, residential and commercial buildings, airports, highways, and foundation engineering projects.
The machine integrates an automatic longitudinal bar feeding system, longitudinal bar detection and positioning welding system, spiral bar winding and welding system, and automatic cage discharge system. The entire welding process operates without manual intervention.
The equipment offers high welding efficiency, with the welding time for a single longitudinal bar completed in less than 35 seconds. The welding duration for each weld point can be configured and stored according to specific process requirements. This significantly reduces labor requirements while greatly improving production efficiency.
The system ensures continuous and rapid welding performance. A 9–12 meter rebar cage framework can generally be completed within 20 minutes, and the spiral bar winding and welding process can typically be finished in approximately 25 minutes.
![Rebar Cage Forming Machine]( "Rebar Cage Forming Machine")
Welding quality is stable and reliable, with no incomplete or false welds. Precise control of welding time and welding position reduces material consumption and ensures consistent product quality. The system supports multiple preset rebar cage specifications. Operators can directly retrieve stored parameters and perform one-click operation via the touchscreen interface. The streamlined production mode is simple, intuitive, and highly automated.
The finished products fully comply with industry standards and technical specifications. In traditional manual rebar cage fabrication, project supervisors usually conduct daily on-site inspections. After adopting the Fully Automatic Rebar Cage Forming Machine YGTZ2500-12, the system automatically monitors all operational data, performs real-time welding detection and recording, and promptly reports monitoring information, ensuring stable and reliable production quality.
![Rebar Cage Forming Machine]( "Rebar Cage Forming Machine")
Comparison with Traditional Equipment
| Comparison Item | CNC Steel Cage Welding Workstation | Traditional Cage Rolling Welding Machine | (Upgraded) Dual-Station CNC Steel Cage Welding Workstation |
Welding Type | Fully automatic main bar + spiral welding | Spiral automatic, main bars manually welded | Fully automatic main bar + spiral welding |
Welding Method | Automatic CO₂ gas shielded welding | Manual welding, inconsistent quality | Automatic CO₂ gas shielded welding |
Cage Diameter | 790–2340 mm, no mold replacement | 800–2200 mm, requires multiple molds | 790–2340 mm, no mold replacement |
Diameter Adjustment | CNC automatic support ring adjustment | Manual mold replacement | CNC automatic adjustment |
Feeding Mode | CNC chain conveyor, unmanned | Manual bar insertion | CNC chain conveyor |
Spiral Bar Diameter | 6–16 mm | 6–16 mm | 6–16 mm |
Cage Docking | Automatic measurement compensation | Manual correction required | Automatic compensation |
Single/Double Main Bars | Supported | Single only | Supported |
Single/Double Spiral | Supported | Single only | Supported |
Dual Main Bars (Horizontal) | Supported | Not supported | Supported |
Inner Support Ring Adjustment | CNC automatic | Manual | CNC automatic |
Number of Main Bars | 4–128 bars | Mold-dependent | 4–128 bars |
Operators Required | 1 person | 4–6 persons | 1 person |
Production Capacity (Ø1600 mm) | 10–12 cages/shift | 6–8 cages/shift | 20–24 cages/shift |
Main Bar Welding Time (12m) | 15 min/section | Unstable manual control | 15 min/section |
Spiral Welding Time (12m) | 15 min/section | 20 min/section | 15 min/section (synchronized) |
Technical Specifications
Model: YGTZ2500-12
Cage Inner Diameter | 800–2500 mm |
Cage Length | 12 m |
Max Cage Weight | 6000 kg |
Main Bar Diameter | 16–50 mm |
Main Bar Type | Single / Double |
Main Bar Welding Frequency | 0–3 times |
Main Bar Single Weld Time | 0–2 s |
Single Main Bar Welding Time | 30–50 s |
Main Bar Feeding | Pneumatic automatic positioning |
Bar Alignment | Servo automatic positioning |
Alignment Accuracy | ±3 mm |
Coil (Spiral) Bar Diameter | 5–14 mm |
Spiral Type | Single / Double |
Spiral Pitch | 50–500 mm |
Spiral Pitch Accuracy | ±2 mm |
Spiral Welding Mode | Full / Intermittent / Self-adjustable |
Spiral Single Weld Time | 0–1 s |
Spiral Pay-off Speed | 0–50 m/min (VFD adjustable) |
Spiral Carriage Speed | 0–3 m/min |
Spiral Straightening | Dual-line roller straightening |
Spiral Load Capacity | 6000 kg |
Cage Rotation Speed | 0–10 r/min |
Cage Rotation Accuracy | ±0.2° |
Head Travel Speed | 0–3 m/min |
Cage Unloading | Automatic trolley lateral movement |
Cage Lifting Supports | 6 sets |
Lifting Mode | Hydraulic system |
Hydraulic Pressure | 10 MPa |
Oil Pump Pressure | 10 MPa |
Air Pressure | 0.9 MPa |
Welding Units | 2 sets (main & spiral movable welding devices) |
Total Rated Power | 100 kW (including 8 welding machines) |
Power Supply | 380V / 50Hz |
Stored Cage Programs | 30 sets |
Intelligent Bar Length Memory | Standard |
Inner Support Rings | 6 pieces |
Support Ring Spacing Range | 1700–2000 mm |
Adjustment Mode | CNC programmable |
Operators Required | 1–2 persons |
Dimensions (L×W×H) | 36 m × 8 m × 3 m |
Total Weight | Approx. 38 tons |
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Main Components List
| Component | Model | Specification | Quantity |
Main Turntable Servo Motor | 7.5 kW | — | 1 |
Fixed-Length Travel Servo Motor | 2.3 kW | — | 1 |
Trolley Travel Motor | 4 kW | — | 1 |
Drum Rotation Motor | 7.5 kW | — | 1 |
Spiral Travel Motor | 3 kW | — | 1 |
Spiral Straightening Motor | 5.5 kW | — | 2 |
Industrial PLC Controller | XD5E | — | 1 |
Touchscreen (HMI) | PI Series | — | 1 |
Gear Reducer | YPCD | — | — |
Cylinder | RONAY | — | — |
Welding Machine | 500 | — | 8 |
Frequency Inverter | — | — | — |
Electrical Components | Customized | Relays / Contactors / Proximity Switches | — |
Three-Phase Motor | — | Three-phase asynchronous motor | — |
