Reinforcing Mesh Welding Machine Solution
In order to help our customers better understand the reinforcing mesh welding machine and how to select the right one based on their specific needs, we have developed a comprehensive solution. This solution ensures high quality and performance, while also offering the flexibility to create customized solutions tailored to your unique requirements. Our goal is to match your mesh welding production needs with the perfect machine.
This article explores the advantages, technical specifications, and components of the reinforcing mesh welding machine. We will detail how its design and features contribute to high-efficiency production. Additionally, we will look at how RKM’s reinforcing mesh welding machine integrates advanced technology to ensure exceptional performance.
1. Advantage of Pneumatic Machines
Pneumatic machines offer several advantages in the production of reinforcing mesh, primarily due to their efficient operation, reliable performance, and cost-effectiveness. The following benefits highlight why pneumatic machines are an ideal choice for mesh welding:
- Easier Maintenance: Pneumatic systems have fewer mechanical components, reducing the risk of mechanical failure and minimizing maintenance requirements.
- Consistent Welding Pressure: Each welding point receives the same welding pressure, which ensures uniform welding quality and improved consistency.
- High Welding Power: Pneumatic machines are equipped with enough welding power to weld up to 12mm rebar, providing flexibility for different mesh types.
- Fast Welding Speed: Welding speeds can reach up to 80-100 times per minute, significantly improving production efficiency.
- Efficient Electrode Operation: Welding electrodes do not require constant operation; they only need to be disconnected using the electromagnetic valve.
- Precision Control: The inclusion of a precision pressure reduction valve ensures minimal error (±0.5%) and high flow for optimal mesh production.
2. Technical Parameters
The Reinforcing Mesh Welding Machine offers a range of technical specifications designed to meet the needs of modern mesh production. Below is a table summarizing the key parameters:
| Model | DP-GW-2500B |
|---|---|
| Wire Diameter | 4-12mm |
| Line Wire Space | 100-250mm |
| Cross Wire Space | Min. 50mm |
| Width of Mesh | Max. 2500mm |
| Length of Mesh | Max. 6m |
| Welding Points | 24pcs |
| Welding Transformers | 150kVA x 12pcs |
| Welding Speed | Max. 80-100 times/min |
| Line Wire Feeding | Pre-straightened & pre-cut |
| Cross Wire Feeding | Pre-straightened & pre-cut |
| Air Compressor | 3.7m³/min |
| Weight | 8.2T |
| Machine Size | 20 x 4.7 x 2.3m |
Key Features:
- High-Precision Production: With the ability to produce mesh with tight tolerances, the machine ensures that the welds are consistent and meet the required standards.
- Customizable Mesh Sizes: The machine can be adapted to produce mesh of varying dimensions, making it suitable for different construction applications.
- Increased Efficiency: The high-speed welding capability increases productivity while maintaining quality, which is essential in meeting the high demand in the construction industry.
3. Wire Feeding System
The Wire Feeding System plays a vital role in ensuring smooth and uninterrupted mesh production. The system consists of two primary mechanisms: Longitude Wire Feeding and Cross Wire Feeding.
Longitude Wire Feeding
- Specially Designed Steel Tube: This design simplifies the feeding of line wires, ensuring smoother operation.
- Servo Motor & Planetary Reducer: Panasonic's servo motor, combined with a planetary reducer, facilitates efficient wire feeding, even for long, extra wires.
- Automatic Clamping: Line wires are automatically clamped by SMC air cylinders, removing the need for manual adjustments for different wire diameters.
- Automatic Slot Tunnel Lifting: The slot tunnels lift automatically while pulling the mesh, which reduces wear on the welding electrodes.
Cross Wire Feeding
- Feeder Design: The cross-wire feeder is specially designed to continuously feed a bulk of wires into the system. It can handle up to 1T of wire.
- Motor & Reducer: A motor and hardened reducer work together to ensure the smooth and continuous feeding of cross wires.
- Servo Motor & Planetary Reducer: Panasonic's servo motor, planetary reducer, and coupling work together to control the precise falling of cross wires, ensuring high torque, accuracy, and stability.
4. Mesh Welding System
The Mesh Welding System is at the core of the machine’s efficiency. It is designed to deliver powerful and precise welds, ensuring high-quality mesh production.
SMC Custom-Made Air Cylinders: The welding system utilizes SMC M90 bally air cylinders, which provide a 20% increase in output power and 30% less air consumption. These air cylinders ensure a reduction in power consumption, saving up to 50% compared to older machines.
Welding Electrode Design: Each welding electrode is controlled by one SMC bally air cylinder, and the electrodes are water-cooled to prevent overheating.
Copper Plates for Electrical Conduction: A 600mm² upper copper plate and 1000mm² lower copper plate connect the welding electrodes and transformers, facilitating easier electric conduction and extending the service life of the equipment.
5. Mesh Pulling System
The Mesh Pulling System ensures precise mesh pulling, which is crucial for maintaining correct spacing between longitudinal and cross wires.
High Precision: A Panasonic 2kw servo motor and planetary reducer control the mesh pulling system, ensuring high precision and power.
Automatic Adjustments: The up and down motion of the pulling hook is controlled by SMC air cylinders.
Cross Wire Spacing Adjustments: The mesh pulling distance (i.e., the cross-wire space) is easily adjustable via the PLC touch screen.
- Reliable Components: The system uses a J&T brand pulling rack, which ensures more accurate pulling with less noise. Additionally, the Igus drag chain imported from Germany provides high-quality performance and durability.
6. Electric Parts
The Reinforcing Mesh Welding Machine features reliable electrical components that ensure smooth operation and superior performance.
| Electrical Components | Brand |
|---|---|
| PLC | Panasonic (Japan) |
| Touch Screen | Weinview (Taiwan) |
| Low-Voltage Apparatus | Schneider (France) |
| Switch | ABB (Sweden/Switzerland) |
| Air Switch | Schneider (France) |
| Power Supply | Delta (Taiwan) |
| Servo Driver | Panasonic (Japan) |
| Wire Terminal | Phoenix (Germany) |
| SCR | Infineon (Germany) |
These components, sourced from leading global manufacturers, ensure that the machine runs smoothly and reliably, minimizing downtime and enhancing productivity.
7. Auxiliary Equipment
To complement the main machine and ensure optimal performance, RKM also provides auxiliary equipment.
Wire Straightening and Cutting Machine GT4-12
This machine is used for straightening and cutting wires to the required lengths.
| Technical Parameters | |
|---|---|
| Wire Diameter | 4mm-10mm |
| Cutting Length | 500-6000mm |
| Speed | 52m/min |
| Straightening Motor | 11kw |
| Cutting Motor | 5.5kw |
| Straightening Accuracy | ±2mm |
| Cutting Accuracy | ±10mm |
| Machine Size | 2940×800×1100mm |
| Weight | 1200KG |
Close Type Water Cooling Device MG-15C (D)
For cooling purposes, this device maintains optimal temperatures for the welding process.
| Technical Parameters | |
|---|---|
| Input Power | 16.31kw |
| Cooling Capacity | 41.8kw |
| Refrigerant | R22 |
| Flow Rate | 7.17m³/h |
| Machine Size | 1.8×1×1.6m |
| Weight | 750KG |
Air Compressor & Associated Equipment
An air compressor, air tank, and associated dryer are provided to supply the necessary compressed air for the system.
| Technical Parameters | |
|---|---|
| Air Capacity | 3.7m³/min |
| Air Pressure | 0.8MPa |
| Motor Power | 22kw |
| Machine Size | 1.2×0.8×1.12m |
| Weight | 380KG |
8. Weldable Rebar Types
The machine is capable of welding finished mesh round bars and ribbed bars, with a welding depth of 15%.
9. Sending Engineer
RKM can provide on-site installation, debugging, and training services with the best technicians. This ensures that customers get the most out of their equipment and are fully trained to use the system efficiently.
