Rebar Cage Welding Workstation
1. Fully Automatic & Unmanned Operation: Integrates automatic longitudinal bar welding and spiral winding welding in one system, enabling true unmanned production with only 1–2 operators required.
2. High Efficiency & Large Output Capacity: A 9–12 m cage can be completed within 20–25 minutes, with significantly higher shift output compared to traditional rolling welding machines.
3. Precision Control & Superior Welding Quality: CNC positioning, automatic CO₂ gas shielded welding, and real-time monitoring ensure accurate alignment (±3 mm) and stable weld quality with no false or missed welds.
4. Flexible Configuration & Intelligent Management: Supports wide diameter range (800–2500 mm) without mold change, stores up to 30 cage parameter sets, and enables one-touch operation via touchscreen for fast specification switching
Product Introduction
The Rebar Cage Welding Workstation YGTZ2500-12 is a fully automatic rebar cage welding system developed with independent intellectual property rights. It is widely used in metro construction, bridges, residential and commercial buildings, airports, highways, and foundation engineering projects.
The equipment consists of an automatic longitudinal bar feeding system, main bar detection and positioning welding system, spiral bar winding and welding system, and cage discharge system. The entire welding process is completed automatically without manual intervention.
With high production efficiency, the welding time for a single longitudinal bar is less than 35 seconds. The welding time of each weld point can be configured and stored according to process requirements, significantly reducing labor while greatly improving productivity. The system ensures continuous and high-speed welding. A 9–12 meter rebar cage frame can generally be completed within 20 minutes, and spiral winding and welding can be finished within approximately 25 minutes.
The workstation delivers excellent welding quality with no false or incomplete welds. Welding time and position are precisely controlled, ensuring reliable quality while reducing welding material consumption. The system supports multiple preset cage specifications, allowing operators to directly call stored parameters and perform one-touch operation via the touchscreen interface. The streamlined workflow is simple and intuitive, with a high level of automation. Product quality fully complies with industry standards.
In traditional manual production, project supervisors often inspect the fabrication site daily. With the Rebar Cage Welding Workstation YGTZ2500-12, all production data is automatically monitored, and the welding process is recorded and inspected in real time. The system promptly reports monitoring information, ensuring stable and reliable processing quality.
Equipment Comparison
| Comparison Item | Rebar Cage Forming & Welding Workstation | Traditional Rebar Cage Rolling Welding Machine | (Upgraded) Dual-Station Rebar Cage Forming & Welding Workstation |
Welding Type | Fully automatic longitudinal bar welding + automatic spiral welding (unmanned operation) | Automatic spiral welding; longitudinal bars require manual post-installation and welding | Fully automatic longitudinal bar welding + automatic spiral welding (unmanned operation) |
Welding Method | Automatic CO₂ gas shielded welding, reliable quality | Manual welding, unable to consistently meet welding standards | Automatic CO₂ gas shielded welding, reliable quality |
Applicable Cage Diameter | 790–2340 mm without changing molds | 800–2200 mm; requires multiple mold replacements | 790–2340 mm without changing molds |
Diameter Adjustment | CNC support ring automatic adjustment | Different molds required for different diameters; replacement is cumbersome | CNC support ring automatic adjustment |
Feeding Method | CNC chain conveying system, fully automatic feeding | Manual bar insertion, time-consuming and labor-intensive | CNC chain conveying system, fully automatic feeding |
Spiral Bar Diameter | 6–16 mm | 6–16 mm | 6–16 mm |
Cage-to-Cage Connection | Automatic measurement compensation, zero alignment error | Alignment deviation occurs; requires tightening and secondary adjustment | Automatic measurement compensation, zero alignment error |
Single/Double Longitudinal Bars | Supports both single and double longitudinal bars | Only single longitudinal bars | Supports both single and double longitudinal bars |
Single/Double Spiral Bars | Supports both single and double spiral bars | Only single spiral bars | Supports both single and double spiral bars |
Horizontal Double Main Bars | Achievable | Not achievable | Achievable |
Inner Support Ring Spacing Adjustment | CNC moving welding head, automatic adjustment with high precision | Manual post-adjustment; precision cannot be guaranteed | CNC moving welding head, automatic adjustment with high precision |
Number of Longitudinal Bars | 4–128 bars | Different molds required for different quantities | 4–128 bars |
Required Operators | 1 operator completes entire production process | 4–6 operators required | 1 operator completes entire production process |
Production Capacity | Example: Ø1.6 m cage — 10–12 units per shift | Example: Ø1.6 m cage — 6–8 units per shift | Example: Ø1.6 m cage — 20–24 units per shift |
Longitudinal Bar Welding Time | Example: Ø1.6 m, 12 m cage — 15 minutes per section | Manual control; welding time cannot be guaranteed | Example: Ø1.6 m, 12 m cage — 15 minutes per section |
Spiral Welding Time | Example: Ø1.6 m, 12 m cage — 15 minutes per section | 20 minutes per section | Example: Ø1.6 m, 12 m cage — 15 minutes per section; synchronized with longitudinal welding, total integrated time 15 minutes per section |
Rebar Cage Welding Workstation Specifications
| Parameter | Specification |
Model | YGTZ2500-12 |
Rebar Cage Inner Diameter | 800–2500 mm |
Rebar Length | 12 m |
Maximum Cage Weight | 6000 kg |
Coil (Spiral) Bar Diameter | 5–14 mm |
Spiral Bar Pitch | 50–500 mm |
Longitudinal Bar Diameter | 16–50 mm |
Hydraulic System Pressure | 10 MPa |
Rated Total Power | 100 kW (including 8 welding machines) |
Overall Dimensions (L×W×H) | 36 m × 8 m × 3 m |
Welding Head Travel Speed | 0–3 m/min |
Spiral Carriage Travel Speed | 0–3 m/min |
Cage Rotation Speed | 0–10 rpm |
Total Machine Weight | Approx. 38 tons |
Longitudinal Bar Welding Times | 0–3 times |
Single-Point Welding Time (Longitudinal Bar) | 0–2 s/point |
Spiral Welding Mode | Full Welding / Staggered Welding / Adjustable |
Single-Point Welding Time (Spiral Bar) | 0–1 s/point |
Spiral Configuration | Single Spiral / Double Spiral |
Longitudinal Bar Configuration | Single Bar / Double Bar |
Power Supply | 380V / 50Hz |
Cage Discharge Method | Automatic trolley lateral transfer structure |
Mobile Welding Devices (Longitudinal & Spiral) | 2 sets |
Intelligent Rebar Length Memory | Standard configuration |
Longitudinal Bar Feeding Method | Pneumatic automatic positioning and feeding |
Rebar Alignment Method | Servo automatic positioning |
Rebar Alignment Accuracy | ±3 mm |
Single Longitudinal Bar Welding Time | 30–50 s/time |
Cage Lifting Supports | 6 sets |
Cage Lifting Method | Hydraulic system control |
Oil Pump Pressure | 10 MPa |
Air Pump Pressure | 0.9 MPa |
Cage Rotation Accuracy | ±0.2° |
Cage Support Method | Hydraulic support (stable and reliable) |
Spiral Pitch Accuracy | ±2 mm |
Stored Cage Data Capacity | 30 sets |
Required Operators | 1–2 persons |
Spiral Pay-off Speed | 0–50 m/min (variable frequency adjustable) |
Spiral Straightening Method | Dual-line roller straightening |
Spiral Load Capacity | 6000 kg |
Mold Ring Support Method | Hydraulic support (stable and reliable) |
Number of Inner Support Rings | 6 |
Inner Support Ring Spacing Adjustment Range | 1700–2000 mm |
Inner Support Ring Adjustment Method | CNC program-controlled |
Main Components List
| Component Name | Model | Manufacturer | Remarks |
Main Turntable Servo Motor | 7.5 kW | Zhejiang Huixunjun | 1 set |
Fixed-Length Traveling Servo Motor | 2.3 kW | Zhejiang Huixunjun | 1 set |
Trolley Traveling Motor | 4 kW | Shandong Hongyu | 1 set |
Roller Rotation Motor | 7.5 kW | Shandong Hongyu | 1 set |
Spiral Traveling Motor | 3 kW | Shandong Hongyu | 1 set |
Spiral Straightening Motor | 5.5 kW | Shandong Hongyu | 2 sets |
Industrial PLC Controller | XD5E | Jiangsu Xinjie | 1 set |
Touch Screen | PI Series | Fujian Wecon | 1 set |
Gear Reducer | YPCD | Hangzhou, Zhejiang | — |
Pneumatic Cylinder | RONAY | Wenzhou, Zhejiang | — |
Welding Machine | 500 Model | Lugong | 8 sets |
Frequency Inverter | — | Zhejiang Yikong | — |
Electrical Components | — | Zhejiang CHINT (Customized) | Relays, Contactors, Proximity Switches |
Three-Phase Motor | — | Rongcheng Shuoli | Three-phase Asynchronous Motor |
