Smart Reinforcing Bar Processing Equipment Cluster Deployed at Key Infrastructure Project Daily Production Capacity Exceeds 50 Tons, Setting New Industry Benchmark

Recently, a smart reinforcing bar processing plant supported by our company's core equipment commenced operations at a major infrastructure project, marking a new phase of “full-process intelligent manufacturing” in China's reinforcing bar processing industry. Equipped with our company's intelligent equipment cluster—including fully automated CNC rebar cage roll welders and magnetic-fed four-head shearing/bending workstations—the plant achieves an average daily processing capacity of 40 tons, peaking at 50 tons. This represents a 300% efficiency boost over traditional methods while reducing labor costs by 80%, delivering a groundbreaking solution for enhancing infrastructure project quality and efficiency.

Three Core Advantages Redefine Rebar Processing Standards

1. Intelligent Production Line Cluster: Unmanned Transformation from Raw Material to Finished Product

The plant employs our independently developed magnetic feeding intelligent four-head rebar workstation, enabling fully unmanned operation for straight rebar throughout the entire process: “feeding → cutting → bending → stacking.” Equipped with a four-bin magnetic feeding system, it bends four 6-10mm bars simultaneously at 960°/sec, achieving 50 tons per shift—a 233% increase over manual lines. Combined with servo-controlled length systems, processing accuracy reaches ±1mm with 99.9% dimensional compliance. Processing costs drop to just 6 yuan per ton, slashing labor expenses by 94% compared to traditional equipment.

2. AIoT Digital Management: Full-Process Visual Traceability

The digital management platform, built on industrial IoT technology, integrates functions including rebar detailing and material list management, production task scheduling, and cost analysis. By collecting real-time equipment operation data, raw material consumption, and finished product quality information, it enables end-to-end visual tracking across the entire “production-materials-equipment” chain. After implementing this system, the project achieved an 8% increase in raw material utilization and a 15% reduction in scrap waste, fulfilling the management objectives of “saving labor, conserving materials, and reducing effort.”

3. Green Production Innovation: Dual Breakthroughs in Energy Efficiency and Environmental Protection

Equipment clusters utilize high-frequency variable-frequency vibration technology and welding fume purification systems, achieving 98.5% concrete density while purifying over 99% of welding fumes. The entire line maintains power consumption at 25.5kW, reducing energy use by 22% compared to traditional equipment. This annually cuts carbon emissions by approximately 300 tons, perfectly aligning with modern infrastructure's green development requirements.

Benchmark Case Demonstrates Technical Capabilities

This smart processing plant spans 5,760 square meters, primarily handling critical steel reinforcement tasks for bridge cages, beams, columns, and other structural components. By integrating our intelligent equipment, the project team successfully addressed pain points such as complex traditional processing workflows and frequent material transfers. This reduced the processing cycle for T-beam bottom flanges from 7-13 days to just 3-4 days. Notably, the AI-powered visual weld inspection system achieves zero defect detection rate.