CNC Automatic Rebar Cage Forming & Welding Workstation

800–2200 mm

Cage inner diameter

12 m

Cage length

20+ / day

12 m cages, 2 operators

≈1.5%

Steel saved vs. manual lapping

PRODUCT OVERVIEW

Replace point-by-point manual welding with a repeatable, automated process

The Intelligent CNC Rebar Cage Forming & Welding Workstation automatically welds coiled spiral bars to main bars to produce standard pile foundation rebar cages.Manual cage fabrication depends on hand-marked spacing, experience-based spiral pitch and long labor time, which leads to inconsistent diameter and rework at supervision acceptance. This workstation combines automatic main bar feeding, servo positioning, six-axis robot welding and separate frame and spiral stations running in parallel.The HBZN-2200 is a redesign of our existing rebar cage welding workstation. Key structures have been optimized to significantly reduce manufacturing cost while keeping full processing capability.

01

Fast processing

With 2 operators over two shifts, more than 20 finished 12 m cages per day, including all preparation and installation steps.

02

Stable quality

CNC operation gives even main bar and spiral spacing and consistent cage diameter, reducing the burden of supervisor spot checks.

03

Steel saving

Continuous winding and tightening without laps saves about 1.5% of material compared with manual work.

04

Traceable quality

Process parameters are stored and managed by the CNC system for quality control records.

EQUIPMENT COMPOSITION

Four major mechanisms, commissioned independently or run together

Mechanism 1

Automatic Feeding Mechanism

Automatic main bar feeding, online spacing adjustment, length detection and positioning. Pneumatic feeding with servo positioning; alignment accuracy 3 mm.

Mechanism 2

Rebar Cage Frame Welding Mechanism

Positioning welding of main bars to internal stiffener rings to form the cage frame. 6 internal stiffener rings with spacing set by CNC program.

Mechanism 3

Rebar Cage Spiral Winding Mechanism

Coil straightening and winding at the set pitch. Drum-type dual-line straightening with payout speed adjustable by frequency converter.

Mechanism 4

Spiral Bar Automatic Welding Robot

A six-axis robot follows the spiral bar path and welds each intersection of spiral bar and main bar. Welding modes are selectable.Supporting systems: hydraulic lifting support system (4 sets), electric rebar cage supports, single-side cage unloading device, and a CNC operating system (touch screen + PLC).

CORE ADVANTAGES

Built to remove the slow, inconsistent steps of manual cage making

01

Automatic feeding, online spacing adjustment

Main bar spacing is adjusted online with low positioning error. Length detection holds the main bar end position within 2 mm and spacing within 10 mm.

02

Six-axis robot automatic welding

Spiral bar and main bar intersections are welded automatically with no manual involvement, directly saving welder positions.

03

Suits multiple cage types

Welds single main bar with single stirrup, single main bar with double stirrups, and double main bars with double stirrups.

04

Servo fixed-spacing structure

A servo system positions the main bars for even circumferential distribution and small error.

05

Automatic ring-expanding device

Internal stiffener rings are easy to install. The expanding action is program-controlled, with action time set on the parameter page.

06

Single-side cage unloading

Hydraulic supports lower, the door opens and the finished cage comes off the machine, shortening auxiliary time per cage cycle.

07

Parallel frame and spiral stations

Frame welding and spiral bar welding proceed separately without waiting for each other, multiplying overall line efficiency compared with single-station rolling welders.

08

Automated CNC system

Touch-screen operation stores up to 20 sets of rebar cage process data with an intelligent rebar length memory. Recall data when changing specifications, with no re-calibration of tool setting.

09

Standardized finished cages

Consistent diameter and evenly distributed main bars make positioning easy when joining cage sections, saving on-site lifting and joining time.

TECHNICAL PARAMETERS

HBZN-2200 specifications

Basic Specifications Rebar & Welding Motion & Accuracy Hydraulics & Control

Parameter	Value
Model	HBZN-2200
Rebar cage inner diameter	800–2200 mm
Rebar cage length	12 m
Maximum rebar cage weight	6,000 kg
Complete machine weight	25 t
Overall dimensions (L × W × H)	35 m × 8 m × 3 m
Power supply	380 V / 50 Hz
Rated total power	85 kW (including 8 welding machines)
Number of operators	1–2 persons

Parameter	Value
Main bar diameter	16–32 mm
Spiral bar (coil) diameter	8–14 mm
Spiral bar pitch	70–300 mm
Spiral bar type	Single winding / double winding
Main bar type	Single main bar / double main bars
Main bar welding passes	0–3 passes
Spiral bar welding mode	Full weld / staggered (quincunx) weld / self-adjusting
Single-point welding time, spiral bar	0–1 s per point
Spiral bar welding speed	0–16 m/min, servo adjustable

Parameter	Value
Machine head travel speed	0–3 m/min
Spiral winding carriage speed	1 m/min (design speed)
Cage rotation speed	0–10 r/min
Spiral bar payout speed	0–50 m/min, frequency converter adjustable
Spiral bar straightening	Drum-type dual-line straightening
Main bar feeding	Pneumatic automatic feeding
Rebar alignment	Servo positioning
Rebar alignment accuracy	3 mm
Spiral bar spacing accuracy	±2 mm
Cage rotation accuracy	±0.2°
Main bar end position control	≤ 2 mm
Main bar spacing control	≤ 10 mm

Parameter	Value
Hydraulic station / oil pump pressure	10 MPa
Air pump pressure	0.8 MPa
Cage lifting	Hydraulic system, 4 support sets
Cage support	Electric support
Cage unloading	Single-side door
Cage diameter adjustment	Motor-driven linkage, 800–2200 mm, no molds required
Stored process data sets	Up to 20 sets, with intelligent rebar length memory
Internal stiffener rings per cage	6
Stiffener ring spacing range	1500–2000 mm, set by CNC program
Spiral winding load capacity	6,000 kg
Roller spacing adjustment	500–1,400 mm
Control system	Touch screen + PLC

Parameter	Value
Model	HBZN-2200
Rebar cage inner diameter	800–2200 mm
Rebar cage length	12 m
Maximum rebar cage weight	6,000 kg
Complete machine weight	25 t
Overall dimensions (L × W × H)	35 m × 8 m × 3 m
Power supply	380 V / 50 Hz
Rated total power	85 kW (including 8 welding machines)
Number of operators	1–2 persons

Parameter	Value
Main bar diameter	16–32 mm
Spiral bar (coil) diameter	8–14 mm
Spiral bar pitch	70–300 mm
Spiral bar type	Single winding / double winding
Main bar type	Single main bar / double main bars
Main bar welding passes	0–3 passes
Spiral bar welding mode	Full weld / staggered (quincunx) weld / self-adjusting
Single-point welding time, spiral bar	0–1 s per point
Spiral bar welding speed	0–16 m/min, servo adjustable

Parameter	Value
Machine head travel speed	0–3 m/min
Spiral winding carriage speed	1 m/min (design speed)
Cage rotation speed	0–10 r/min
Spiral bar payout speed	0–50 m/min, frequency converter adjustable
Spiral bar straightening	Drum-type dual-line straightening
Main bar feeding	Pneumatic automatic feeding
Rebar alignment	Servo positioning
Rebar alignment accuracy	3 mm
Spiral bar spacing accuracy	±2 mm
Cage rotation accuracy	±0.2°
Main bar end position control	≤ 2 mm
Main bar spacing control	≤ 10 mm

Parameter	Value
Hydraulic station / oil pump pressure	10 MPa
Air pump pressure	0.8 MPa
Cage lifting	Hydraulic system, 4 support sets
Cage support	Electric support
Cage unloading	Single-side door
Cage diameter adjustment	Motor-driven linkage, 800–2200 mm, no molds required
Stored process data sets	Up to 20 sets, with intelligent rebar length memory
Internal stiffener rings per cage	6
Stiffener ring spacing range	1500–2000 mm, set by CNC program
Spiral winding load capacity	6,000 kg
Roller spacing adjustment	500–1,400 mm
Control system	Touch screen + PLC

Specifications are for the standard model and may be adjusted for customized configurations. Contact us to confirm parameters for your project.

WORKING PROCESS

From specification to finished cage in six steps

No manual involvement is needed in any welding step of the whole process.

STEP 1

Recall specification

On the touch screen, recall stored process data (up to 20 sets) or create a new specification.

STEP 2

Automatic main bar feeding

Pneumatic feeding places main bars at the set quantity and spacing; servo positioning aligns them and length detection confirms end positions.

STEP 3

Internal stiffener ring installation

Place the inner ring on its support and press install; the support expands and positions it automatically.

STEP 4

Frame welding

The welding head travels along the cage body and welds each main bar to the internal stiffener rings to form the cage frame.

STEP 5

Spiral winding and welding

Coil is straightened by the drum-type dual-line straightener and wound at the set pitch while the six-axis robot welds the intersections.

STEP 6

Cage discharge

Hydraulic supports lower, the door device opens and the finished cage comes off the machine.

CONTROL SYSTEM

Touch screen + PLC CNC system

• Store, recall and modify up to 20 rebar cage specification sets
• Main bar setup wizard guides the feeding parameters
• Action delay of each actuator can be set independently
• Automatic alarm when a position sensor times out without reaching position
• Independent start / stop / pause / reset control of main bar operation

3D layout: main bar feeding station, frame welding head, spiral winding mechanism and cage discharge device.

APPLICATION FIELDS

Centralized prefabrication of pile foundation rebar cages

Especially suited to batch production for bored cast-in-place piles and large-diameter pile foundation projects.

01

Metro

Station and tunnel foundation piles

02

Bridges

Large-diameter bored pile cages

03

Buildings

High-rise pile foundations

04

Airports

Runway and terminal foundation works

05

Expressways

Viaduct and bridge piling

06

Foundation Engineering

Batch production for bored cast-in-place piles

Applicable practice: stiffener ring spacing

Pile cage design notes commonly call for reinforcing rings every 2 m, and every 1.5 m when the pile length exceeds 20 m. The HBZN-2200 sets ring spacing from 1500 to 2000 mm by CNC program. Always follow your project drawings and local codes.

FAQ

Frequently asked questions about the HBZN-2200

What is a rebar cage welding workstation used for?

It is automated equipment for prefabricating pile foundation rebar cages. It feeds main bars, winds spiral bars around them and welds the intersections automatically, producing standard cages for bored cast-in-place piles and large-diameter pile foundations in metro, bridge, building, airport and expressway projects.

What cage diameter and length can the HBZN-2200 handle?

The HBZN-2200 produces rebar cages with an inner diameter of 800–2200 mm and a length of 12 m. Cage diameter is adjusted by a motor-driven linkage mechanism, so no molds are needed to change size within this range.

How long does it take to produce one 12 m rebar cage?

Cycle time depends on cage diameter and reinforcement configuration. With the standard configuration and two operators over two shifts, the workstation can process more than 20 finished 12 m cages per day, including material preparation, welding, stiffener ring, inspection tube and guide spacer installation. Contact us for cycle times for your specific cage.

How many operators does the machine need?

Only 1–2 operators are needed. Main bar feeding, frame welding, spiral winding and spiral-to-main-bar welding are all completed automatically, with limited manual assistance.

Can it weld double main bars and double spiral bars?

Yes. It handles three pile foundation reinforcement configurations: single main bar with single stirrup, single main bar with double stirrups, and double main bars with double stirrups.

What power supply and floor space are required?

The machine runs on 380 V / 50 Hz with a rated total power of 85 kW, including 8 welding machines. The overall dimensions are 35 m × 8 m × 3 m and the complete machine weighs about 25 t.

Do you provide overseas installation and training?

Please contact our sales team to discuss installation, commissioning, operator training and remote technical support for your project and destination.

It is automated equipment for prefabricating pile foundation rebar cages. It feeds main bars, winds spiral bars around them and welds the intersections automatically, producing standard cages for bored cast-in-place piles and large-diameter pile foundations in metro, bridge, building, airport and expressway projects.The HBZN-2200 produces rebar cages with an inner diameter of 800–2200 mm and a length of 12 m. Cage diameter is adjusted by a motor-driven linkage mechanism, so no molds are needed to change size within this range.Cycle time depends on cage diameter and reinforcement configuration. With the standard configuration and two operators over two shifts, the workstation can process more than 20 finished 12 m cages per day, including material preparation, welding, stiffener ring, inspection tube and guide spacer installation. Contact us for cycle times for your specific cage.Only 1–2 operators are needed. Main bar feeding, frame welding, spiral winding and spiral-to-main-bar welding are all completed automatically, with limited manual assistance.Yes. It handles three pile foundation reinforcement configurations: single main bar with single stirrup, single main bar with double stirrups, and double main bars with double stirrups.The machine runs on 380 V / 50 Hz with a rated total power of 85 kW, including 8 welding machines. The overall dimensions are 35 m × 8 m × 3 m and the complete machine weighs about 25 t.Please contact our sales team to discuss installation, commissioning, operator training and remote technical support for your project and destination.