Bridge Rebar Cage Welding Robot | haibao robot

Project photographs and equipment references

haibao robot · CUSTOMER APPLICATION

Gantry Welding Automation for Bridge Pier-Cap Reinforcement

The Jiangsu Jiaojian application demonstrates a dedicated welding system for reinforcement assemblies used in bridge pier caps. The ZJ GJ-5000 gantry machine combines dual welding heads with repeatable fixture positioning.

Why automate reinforcement welding?

Manual welding of large reinforcement assemblies demands repeated positioning and sustained operator effort. Fixture accuracy, joint access and a consistent welding sequence are central to repeatable production. This application uses a purpose-built gantry rather than treating each weld as an isolated manual operation.

Dual heads and alternating fixtures

The machine uses a gantry structure with two welding heads and two sets of forming fixtures, comprising four fixture positions. While one pair is being welded, the next pair can be prepared in the designated loading area. The arrangement reduces waiting between welding and loading, subject to the required guarding and safe operating procedure.

Production sequence

Break the reinforcement drawing into individual bar shapes, form the bars using CNC bending equipment, and place them in the matched fixtures. Select the taught welding sequence and weld the first pair of assemblies while preparing the next fixture pair. A handheld teaching system supports setup and operation.

Planning the installation

The original installation specification calls for a level, sheltered indoor area with at least 200 mm of hardened flooring, 380 V / 50 Hz power and 30 kW including the welding equipment. The stated work area is 6 m wide, with length equal to twice the longest reinforcement assembly plus 4 m. Foundation and utilities must be checked for the actual installation.

Consumables and process review

The published configuration uses CO2 shielding gas, 1.6 mm welding wire and consumables for a 500-class gas-shielded welding source. Bar grade, diameter, joint geometry and welding requirements should be reviewed before confirming a production process or quoting output.

Request an application review

Send reinforcement drawings, bar grades and diameters, assembly dimensions, daily output and available floor space.

haibao robot
Shao Yicheng · Key Account Project Director · International Welding Engineer (IWE)
Email: masterhyper@163.com
Phone / WhatsApp: +86 177 5158 3908
Office: +86 519 8837 0688