Reinforcement Cage Automatic Welding Workstation
Case 1：China Railway 10th Bureau Group-High-speed Railway Bridge Pile Foundation Reinforced Cage Project
Project Overview
The client, a leading state-owned enterprise in China's high-speed rail construction, undertook the fabrication of steel cages for bridge pile foundations in a cross-provincial high-speed rail project. The monthly requirement was 800 sections of 12-meter standard steel cages, with tight deadlines and stringent quality standards. Traditional manual welding faced three major challenges: low efficiency, inconsistent quality, and high labor costs.
configuration
A customized dual-station intelligent steel bar cage welding workstation is designed, featuring: two six-axis welding manipulators, a servo-driven winding system, an industrial PLC CNC control panel, and two automated feeding/lifting conveyors. The system ensures ±0.5mm spacing control for main bars and supports flexible production of 1.2-2.0m diameter steel cages.
customer feedback
Efficiency achieved a remarkable 2.1-fold increase
With just two workers per shift, the daily output reached 22 12-meter steel cages, surpassing the traditional six-person team's output of 7 cages per day. This accelerated the monthly processing target by 15 days, ensuring timely completion of bridge pile foundation construction milestones.
Stable and controllable quality
The welding points of main and spiral bars are precisely positioned, with a 99.5% weld qualification rate and a 100% first-time acceptance rate for the steel cage, fully meeting the stringent structural precision requirements of high-speed rail projects.
Significant cost reduction
Annual labor savings of 1.2 million yuan, 1.8% lower material waste rate than traditional methods, 65% reduction in overall processing costs, and reduced on-site welding safety risks.
Project Value
The equipment has operated stably for 12 months, processing over 26,000 steel cage sections cumulatively. It has become the core intelligent equipment for high-speed rail steel cage production, helping clients achieve production transformation through 'mechanization replacing manual labor and automation reducing workforce.'
Case 2: Zhejiang Communications Engineering Group-Cangtai Expressway Section 7 Project
Project Overview
As a "Demonstration Project of Full-Process Mechanized Construction" in Zhejiang Province, the Cangtai Expressway Section 7 Bridge and Tunnel Project involves a concentrated volume of construction work. The daily demand for steel cage processing reaches 30 sections, requiring equipment to be adapted to the confined tunnel space while achieving millimeter-level precision control.
configuration
The single-station modular steel cage welding workstation integrates automated threading, welding, and cage unloading into a unified process. Equipped with a servo distance adjustment system and intelligent memory length measurement, it enables on-site rapid assembly without requiring long-distance transportation of steel cages.
customer feedback
High adaptability
The modular design enables rapid deployment in tunnel fabrication sites, overcoming challenges like limited space and equipment access. It eliminates the need to dismantle steel cages, thereby reducing secondary assembly losses.
Efficiency doubled
While manual welding required 2 workers per day to produce only 5 sections, the equipment's daily output reached 13 sections, meeting the average daily demand of 30 sections and accelerating bridge/tunnel construction to lead the entire project.
Quality control
The welding angle precision is ±0.2 degrees, and the size error of the steel cage is controlled within ±1mm, effectively resolving the quality issues of steel bar displacement and unstable weld points in traditional welding methods.
Project Value
After the equipment went into operation, the steel cage processing in this section achieved full-process automation, saving 800,000 yuan in labor costs annually. This set a benchmark for the 'full-process mechanization' construction of the expressway project and earned commendation from the Zhejiang Provincial Department of Transportation.
Case 3: Shanghai Construction Engineering Machinery Group-Subsurface Continuous Wall Project of Metropolitan Railway
Project Overview
The project involves processing steel cages for three subway stations in Shanghai, including Shuixiang Living Room Station. The steel cages must meet stringent requirements for dimensional accuracy and welding strength, while also fitting into the confined underground workspace. Conventional manual welding methods prove inefficient, with a pass rate below 90%.
configuration
The intelligent welding robot workstation for underground continuous wall reinforcement cages, featuring the WJ6000 mesh welding robot and HJ1200 truss welding robot, integrates an industrial camera-based visual positioning system to achieve 80% intelligent construction of components.
modular title
Quality breakthrough
The pass rates for weld points and seams were raised to 98% and 99% respectively, with the finished steel cages achieving 100% first-time acceptance rate – significantly exceeding project requirements.
Staff optimization
The number of on-site workers has been halved, requiring only 2 personnel for equipment monitoring, thereby reducing safety risks and labor costs in underground operations.
Excellent adaptability
The compact equipment enables flexible operations in underground processing areas, meeting the requirements for continuous work in confined spaces and ensuring the timely completion of urban rail projects.
Project Value
The equipment, certified as a 'Shanghai High-Tech Achievement Transformation Project' by the Shanghai Municipal Science and Technology Commission, has processed over 12,000 steel cages for underground continuous walls, setting a benchmark for intelligent construction in urban rail transit underground projects.