Your cage welding machine performance

Even if durability and robust construction are key features of the mbk machines, there comes a point when appropriate modernisation measures must be considered.
Technical progress continues at a rapid pace, so that older cage welding machines can no longer ensure the customary stable production processes and the competitive advantage that has been built up over many years may be jeopardised. Older cage welding machines not only bring the risk of machine downtime, but also obsolescence and difficulty in obtaining spare parts that are no longer available on the market.
However, it is not always necessary to replace the complete machine. By making various upgrade steps (retrofit actions), an optimisation process can be achieved up to automation level that corresponds to the current state of the art and significantly increases the efficiency of the system.

In addition to its reputation as a solid manufacturer of high-tech, quality machines and systems, mbk is also known in the industry as a maximum service-oriented company. mbk offers modernisation actions in various expansion stages and price classes – all with the aim of increasing efficiency and competitiveness.
The conversion measures used are matched and adapted to the individual purpose of use. This enables a purposeful expansion of the machine application and an increased production output. mbk welding machines can be modified up to a level of automation that enables problem-free integration into a fully automated production process.

The BSM cage welding machines for the production of reinforcement cages for the shaft and concrete pipe industry are designed with a high production capacity. Type series appropriate for different requirement profiles are available. All of the types incorporate features such as stable construction, tightest production tolerances, a high degree of compatibility, very low maintenance and energy costs, maximum user-friendliness, minimum personnel requirements and a large selection of optional accessories.

The BSM type series is available in R (for manufacturing round cages), O (for manufacturing round/oval cages) and with option ROR (round/oval/round cages). The cage diameters range from 220 – 1,700 mm to 900 – 5,200 mm, the number of longitudinal wires from 12/18 to 36/48/60. Standard cage lengths range from 3,000 mm to max. 7,000 mm, wrapping wire pitch 20-200 mm, diameter of the longitudinal wire 4-10/14 mm, wrapping wire diameter 4-12/16mm. The standard welding power (with 2-phase thyristor control) is 100 KVA to 125 KVA and is optionally available with 3-phase medium frequency control 1,000 Hz. All systems are built as a right-hand version as standard, however, they are also available in the left-hand version as an option.

The BSM option ROR made the round/oval/round reinforcement cage reality. This type is also available with various additional benefits such as automatic longitudinal wire feeding from a coil and from a bundle, an automatic cage removal device, and it meets all requirements for a fully automatic operation. The innovative manufacturing method used for ROR reinforcement cages achieves high mechanical strength and offers significant savings potential through the ROR reinforcement cage geometry: only one reinforcement cage is required per concrete pile instead of two.

At mbk, customer orientation means becoming fully involved with the needs and wishes of the customer and finding the most individual solutions tailored to their requirements profile. For example, for selected machines there is the possibility of a maximum diameter extension of the cages produced and diameter reduction and product extension per meter of cage length. Other innovative developments also enable an optimum longitudinal wire diameter (up to max. 14 mm) round/oval. Wrapping wires with an optimum maximum diameter of 16 mm can also be achieved. This is advantageous for the production of highly reinforced cages, such as for jacking pipes. The production of conical cages with a taper smaller than 10 mm/m is also possible with mbk technology.

If it is necessary to weld larger wire diameters together, a more powerful welding technology is used, in which the welding and contact roller is supplied with internal water cooling instead of internal air cooling. This also permits a higher production speed during welding. A speed increase of up to 20% is realistic. This option can still be further increased by speeding up the machine’s production process. Welding transformers or medium-frequency welding transformers with different power capabilities control the welding points.
A significant time saving and maintenance contribution is achieved by using metal carbon as a sliding contact instead of copper grease. This eliminates the need for periodic lubrication with copper grease; no maintenance is required (only a periodic wear check).

A stationary electrohydraulic controlled winding wire cutter, mounted on the welding carriage of the reinforcement welding machine, automatically cuts off the winding wire when the welding process is completed. The cage is moved directly to the removal position without interrupting automatic operation.

Cage removal carriages, designed for different load capacities: Mechanically suitable for loads up to 200 kg, the mechanical system equipped with electro-hydraulic height adjustment can handle up to max. 400 kg.

Types 1 – 4 of the automatic cage removal device depend on machine size and maximum power input and range from a machine size of 170 to 450 and a maximum load capacity of 250 kg – 600 kg.
The cage removal and joining device (KFG) can significantly simplify the working process up to machine size 300 and a load capacity of max. 350 kg. A customer-specific solution for buffering cages/double cages or for transporting cages/double cages is no problem for the specialists at mbk.

The automatic longitudinal wire feed from the bundle (ALZ-B) separates the wires that are presented and aligned on the wire tray, buffers them and loads then into the reinforcement welding machine. The longitudinal wires are fed to the welding machine one after the other. The automatic longitudinal wire feed is also capable of processing wire from coils (ALZ-C) either as the roll straightener variant or the rotor straightener variant. It should be noted here that the roll straightener version is particularly suitable for smooth longitudinal wires, while the rotor straightener version is particularly recommended for profiled and ribbed longitudinal wires.

The wire straightening and cutting machine is a low-cost straightening machine that provides good service in everyday production using a simple operating concept and proven technology.

There are many opportunities for equipping your existing machine with additional features to reintegrate them into an economical production process.
The longitudinal wire feed with a third wheel enables considerable time savings to be achieved: longitudinal wires can be loaded to the third wheel during the running welding process. On unloading the completed welded cage from the machine, the third wheel feeds the preloaded longitudinal wires into the welding machine and production continues immediately.
The double winding wire guide also saves time by avoiding the need to change the wire coil. Additional winding wire decoilers are available up to a capacity of 3,000 kg in the version “with switch-off function” or “motor-driven”. Additional decoiler attachments in different designs, which enable adaptation to the inner diameter of the coil, also improve the efficiency of the production process.

The butt welding unit, which was developed for tensile strength butt welding of wires made of steel, stainless steel and non-ferrous metals, is capable of joining wire diameters from 4 mm up to 12 mm in the standard program.

Wire guide posts, winding wire brakes in different sizes and designs, hydraulic and electric wire cutters, wire coil internal grip with different diameters and many more features complete the portfolio.

The requirements are complicated, the possibilities are versatile. Whether it concerns performance and production stability in an extended environment (up to +55 °C or -20 °C) or a LAN connection to enable remote maintenance, whether particular safety mechanisms (protected areas, photoelectric barriers etc.) are to function correctly, whether an individual machine colour is desired, a spare/wear parts package, a hotline contract or an inspection contract is required – the experts from mbk will find the solution!
And it will be a solution specifically for you! Give us a call!