Adhering to the "intelligent manufacturing" and "dual carbon" strategies, the company empowers traditional infrastructure with technological innovation and has launched a fully automated rebar cage workstation that integrates intelligent sawing, thread processing, grinding and welding, redefining the upper limit of the precision and efficiency of rebar processing in the construction industry.
Four Core Modules Construct an Intelligent Production Closed Loop
Intelligent Hardware Collaborative Network: The workstation integrates digital equipment and sensor clusters to achieve fully automated control of material flow:
* Vibration bed + magnetic stepped loading platform: Multi-sensor real-time monitoring of rebar positioning, pneumatic transmission error ≤3mm;
* Six-axis robotic welding system: 0.1-second response speed, supports full welding/clover welding mode switching, single-point welding accuracy ±0.2°;
* Dynamic mold adjustment technology: CNC support ring intelligently adjusts the cage diameter (800-2500mm), eliminating the need for mold changes, compatible with single and double main reinforcement/stirrup processing.
Cloud-based Flexible Production Management: Utilizing a PLC and industrial-grade touchscreen system, it supports the storage and one-click recall of 7 sets of data templates. Operating parameters (such as reinforcement spacing of 50-500mm and the number of main reinforcement welding cycles) can be programmed online, allowing for rapid switching between multiple specifications of orders.
Data-Driven Capacity Boost:
Double Leap in Efficiency and Quality: A single shift (8 hours) can produce 20 standard 12-meter rebar cages (1.6m diameter). Welding time for main reinforcement and stirrups is reduced to 15 minutes per section, and the processing cost per ton is reduced to 34.3 yuan (a 79% reduction compared to traditional manual processing).
Optimized Consumables for Green Production: Through automatic tensioning technology and precise docking processes (error ≤2mm), stirrup lap loss is reduced by 1.5%, saving over 10 tons of steel annually and simultaneously reducing welding carbon emissions.
Upgraded Industrial Delivery Capabilities:
Innovative Human-Machine Collaboration Model: The workstation requires only one person for operation and monitoring, achieving 2.5 times the capacity of traditional roll welding machines. Combined with the dual-station model (HBZNS-2500), daily production capacity exceeds 24 cages per shift, with labor costs reduced by 85%.
Full Lifecycle Service Network: Equipped with an IoT remote diagnostic interface and a modular spare parts system (including Orui servo motors, Xinje PLCs, etc.), fault response time is improved by 60%.
Intelligent Standards Empower the Future of Infrastructure
This workstation has been widely used in major projects such as high-speed railway pile foundations and cross-sea bridges in China, saving a cumulative labor cost of over 1.296 million yuan per year. The product has passed ISO welding certification.
