GWC-C-500 autoclaved aerated concrete plate mesh welding production line

Our C-500 Design 

Traditional mesh welding involves pre-processing the rebar and then manually feeding it into the machine, which results in slow welding speeds and low production efficiency. Our company, guided by the design philosophy of “maximizing customer benefits,” has developed a series of fully automatic rebar mesh welding production lines. Like all the other automatic mesh welding machines, with a maximum welding speed of up to 100 rows per minute (with a 50mm spacing), the line requires only 1-2 operators, significantly improving production efficiency. The adjustable welding electrode height and transformer voltage help reduce production costs for customers.

Product Features

The design of this equipment is inspired by the most advanced large-scale mesh welding lines from abroad, combined with our company’s more than ten years of experience in manufacturing resistance welding machines. The machine has the following characteristics:

1. This welding machine is a fully automatic specialized welder that processes round steel wire (both cold-drawn and hot-rolled) into rebar mesh. It offers excellent versatility and easy adjustments.
2. The mesh stepping mechanism is controlled by a CNC servo motor, providing high precision and easy adjustments.
3. The separable wire feed reel is reasonably designed, allowing for quick material changes.
4. Changing mesh specifications is straightforward: longitudinal rebar spacing increases in 50mm increments, and adjustments are made by opening or closing the cylinder valves (e.g., changing from 5 to 4 longitudinal rebars takes approximately 3-5 minutes).
5. The height of the welding electrodes and the voltage of the transformer are adjustable, reducing production costs.
6. The crossbar feeding uses a patented magnetic discharge mechanism, offering high speed and efficiency.
7. The user-friendly control interface is easy to operate, intuitive, and highly intelligent.
8. All electrical components are imported, provided by Siemens and Mitsubishi, ensuring stability and reliability.
9. The thyristor trigger unit has low power consumption, small size, and high reliability.
10. The fully automated material collection system reduces labor intensity and improves efficiency.
11. The intelligent fault detection and alarm system facilitates maintenance.
12. The system includes a comprehensive production management module, making operation simple and production fast.
13. The automatic size-cutting mechanism is fast, precise, and of high quality.
14. The control system comprises components from Siemens, Mitsubishi, and Panasonic.

Main Components of the Equipment

This welding machine is a fully automatic specialized welder that processes round steel wire into rebar mesh. It consists of ten main parts (as shown in Figure 1) as follows:

1. Wire feeding mechanism
2. Longitudinal rebar detection
3. Straightening mechanism
4. Traction and storage mechanism
5. Stepping mechanism
6. Main welding machine
7. Crossbar dropping mechanism
8. Cutting mechanism
9. Discharge rack
10. Electrical system
11. Water cooling system
12. Pneumatic system

1. Wire Feeding Mechanism 

The wire feeding mechanism includes a base, a wire feed reel, and a braking system. Bearings are installed between the base and the reel, allowing the reel to rotate smoothly. The braking system adjusts the reel’s flexibility when not feeding material, preventing the rebar coil from unwinding automatically.

2. Longitudinal Rebar Detection 

The longitudinal rebar detection mechanism includes a wire guide and a material shortage detector. When the longitudinal rebar coil runs out, the machine will automatically stop and sound an alarm, with the computer screen displaying a material shortage warning.

3. Straightening Mechanism

The straightening mechanism consists of a base, frame, straightening rollers, and a guiding system. The straightening rollers include both horizontal and vertical rollers, with some mounted on sliders. Adjusting these rollers to the correct position ensures the rebar is properly straightened.

4. Traction and Storage Mechanism

The traction and storage mechanism includes a pressure roller traction system, a storage rack, and detection devices. After passing through the straightening mechanism, the rebar is pulled by the pressure rollers and stored in the rack. The rack is equipped with detection devices to ensure that longitudinal rebars are continuously fed for welding.

5. Stepping Mechanism 

The stepping mechanism consists of stepper traction components, precision adjustment components, and guiding tubes. The stepper traction system uses two sets of pressure rollers to clamp the wire, driven by a servo motor to control the spacing between crossbars. Precision adjustment is made using two sets of straightening rollers to ensure the wire is straight for high-quality mesh production. The guiding tubes ensure that the rebar passes through without bending.

6. Main Welding Machine 

The main welding machine includes the machine frame, air tank, pressure cylinder, material lifting device, welding transformer, crossbar alignment components, crossbar detection devices, and a crossbar adsorption device. The main welding machine is the core component of the entire line. Longitudinal rebars are guided into the welding area, and crossbars are dropped into the welding area by the material dropping mechanism, where magnets hold them in place between the electrodes. Once the crossbar detection device confirms the alignment, the cylinders ensure that the crossbar ends are even. Then, the pressure cylinder engages, and the welding transformer discharges at the set current and time to complete the welding. After welding, the pressure cylinder retracts.

This mechanism ensures that the pressure cylinders provide sufficient force for welding large-diameter mesh, enabling the simultaneous welding of an entire row, thus improving welding efficiency. During mesh pulling, the material lifting device raises the mesh slightly above the electrodes to prevent wear, prolonging the electrode lifespan. Each pressure cylinder is equipped with an individual control switch, allowing for flexible adjustment based on different longitudinal rebar spacings.

7. Crossbar Dropping Mechanism 

This unit consists of a hopper, a separator, and a magnetic discharge system. The pre-processed crossbars are placed into the hopper, separated by the separator, and quickly fed into the electrodes by the magnetic discharge system.

8. Cutting Mechanism 

This component cuts the mesh to the desired length. The grid spacing and cutting position can be adjusted via the control panel.

9. Discharge Rack 

The discharge rack includes a mesh pulling mechanism, a flip-over system, and a stacking cart. The mesh pulling mechanism pulls the cut mesh from the cutting machine, flips it over, and places it into the stacking cart for transport.

Electrical System

The electrical system includes a high and low voltage distribution cabinet and an operation control station, which controls the welding functions and the pneumatic circuits of the production line.

Water Cooling System

The cooling system includes four parts: transformer water cooling, upper electrode water cooling, lower electrode water cooling, and control box water cooling. This ensures the equipment operates normally without damage. (For the cooling water system: to facilitate future maintenance, customers can either build their own system or source one locally. The system should provide a flow rate of 15L/MIN, with the temperature ≤ 30°C.)

Pneumatic System

The pneumatic system includes an air filter to purify compressed air and a silencing device. An external air tank is used to separate dust, water, and oil from the air. The system uses XMC three-unit filters and pneumatic solenoid valves made in Taiwan.