TMA Welding equipment. Wire mesh welding equipment. Welding line for column type wire mesh. Semi-automatic welding line of wire mesh. Automatic welding machine for wire mesh. Mesh welding machine. Parameters of the mesh produced. Welding machine for mesh welding. Full automatic welding machine. Wire Straightening Device. Wire Straightening and Cutting Machine. Semi automatic welding machine. Welding Equipment Layout. Equipment for welded mesh production. Specification of mesh welding equipment. Video of mesh welding equipment operation. Taiwan equipment on Global market.
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WELDING EQUIPMENT


WIRE MESH WELDING EQUIPMENT

Welded reinforcement and masonry mesh, also known as construction mesh, is used for reinforcement of brickwork, foundation screed, plastering works. Besides, such grid is used for fencing of building objects, manufacturing of various pens, enclosures and cages in livestock industry and on poultry farms. In agricultural complexes, the welded mesh is used as a frame for greenhouses. Welded mesh can be used for reinforcement of reinforced concrete structures, monolithic slabs and coatings, monolithic belts, protective steel fences, reinforcement of existing overlaps during reconstruction, any other purposes where it is necessary to install fittings.

Specialized equipment is used in production of reinforcement base. The principle of its work is to weld parallel and intersecting at an angle of 90° wire strings with a diameter of 3 - 5 or 8 mm.

кладочная сетка сварная сетка сварная сетка сварная сетка


WELDING LINE FOR COLUMN TYPE WIRE MESH


Options of column type welding wire mesh

  • 24 welding cylinders.
  • 6 sets of transformers.
  • Auto load of the lateral conductor to the tank.
  • Transverse pitch 20 ÷ 250 mm.
  • Warp wire is loaded into the coiling device and then it is straightened and welded.
  • CNC controls drawing and cutting off the mesh.
  • After welding process finished wire mesh should be removed from the table.
  • Wire diameter: Ø2 ÷ Ø6 mm; Ø6 ÷ Ø12 mm.
  • Longitudinal pitch 100 ÷ 250 mm.
  • Maximum width of wire mesh - 2400mm.
  • Maximum length of wire mesh - 6000mm.
  • Performance: 2 sec/wire (performance depends on wire diameter).



SEMI-AUTOMATIC WELDING LINE OF WIRE MESH

semi-automatic welding line of wire mesh


Options of semi-automatic welding line of wire mesh

  • 2 sets of 120 KVA transformers.
  • Wire diameter: Ø2 ÷ Ø10 mm.
  • Performance: 3.5 sec/wire.
  • Dimensions of produced wire mesh:
    • 2400mm x 3000mm
    • 1800mm x 3000mm
    • 1200mm x 3000mm
  • 12 sets of cylinders controlled independently. Adjustment ability in accordance with the requirements to the product.
  • 2 sets of transformers located on both sides of the machine.
  • 12 sets of cylinders located in the upper part of the machine.
  • Adjustable welding current
  • Semi-automatic loading of wires into the shape.
  • Welding is started by foot switch.
  • High quality final product without any deformation.



AUTOMATIC WELDING MACHINE FOR WIRE MESH

AUTOMATIC WELDING MACHINE FOR WIRE MESH


Min./Max. wire mesh width: 1000-2600 mm
Max. wire mesh width:
2500 mm
Min./Max. wire mesh length: 1000-6000 mm
Line wire diameter (min./max.): 3.0~6.0 mm
Horizontal wire diameter (min./max.): 3.0~6.0 mm
Max. quantity of wires for mesh: 24 pcs.
Line wire pitch: 50 mm
Horizontal wire pitch: 50 mm
Working cycle: to 60-80 crosswire/min.
Brazing speed for one crosswire: 0.1~1.2 sec
(depends on wire diameter)



MESH WELDING MACHINE RG-200S-2400-24T


Technical Specification

Parameters of the mesh produced

Min./Max. wire mesh width 1000 - 2500 mm
Max width of welded mesh 2400 mm
Min/max mesh length 1500 - 6000 mm
Transverse wire diameter (min/max) 5 - 12 mm
Cross wire diameter (min/max) 5 - 12 mm
Max crossing thickness ≤24 mm
Max amount of longitudinal wire per mesh 24 rods
Longitudinal wire pitch 100/150 mm
Transverse wire pitch (min) 50 mm
Vertical wire overhang 25 mm


Production capacity

Welding cycle up to 80 cross bars Ø6 - 7 mm per minute
up to 60 cross bars Ø8 - 12 mm per minute
Welding speed of cross bars 0.5 - 1.2 sec. (depends on wire diameter)
Time of ejection of the welded mesh, return of the gripping forceps, insertion of longitudinal bars 3 - 5 sec.
For bars Ø6mm × Ø6mm welded in 100 mm × 100 mm increments for mesh size: 2400 mm × 3000 mm, production speed 30 - 35 sec/mesh

For bars Ø12 mm × Ø12 mm welded in 100 mm × 100 mm increments for mesh size: 2400 mm × 3000 mm, production speed 43 - 48 sec/mesh



Workpiece material

Soft steel wire, low carbon wire - straight, without scale. The wire should have a clean surface, without any lubrication or dirt.


Equipment characteristics

Number of welding transformers 6 pcs.
Transformer power based on 50% load cycle 200 KVA
Secondary current for transformer 22 кА
Secondary voltage 12 В
Number of welding cylinders 24 pcs (single-impact)
Pressure force 800 kg (hydraulic)
Cylinder size 50 mm


Requirements for engineering networks and communications

Power source 3-phase 380 V 50 Hz ±10%
Power cable cross-section 600 mm² (for one phase)
Fuses with delayed actuation 2000 A (not less than 0.5 sec.)
Air pressure 5 - 8 kg/sm²
Air compressor 5 hp
Cooling water consumption 250 l/min
Water temperature room temperature
These engineering networks and communications are provided by the customer.



Equipment design

EQUIPMENT DESIGN
This drawing is for reference only. The design can be changed according to the customer's requirements.



EQUIPMENT CHARACTERISTICS


Manual feeding of longitudinal wire

feeding of longitudinal wire

The main loading platform is a plug-in trolley, which includes fixed guide channels, to where the operator inserts longitudinal wires and rows of fixed locking clamps.

The cart is activated when the operator has finished loading the longitudinal wire. The locking clamps place longitudinal wire that has been loaded and moves it to the welding point. The welding machine automatically continues welding work.

Applicable wire diameter: 5 - 12 mm


WELDING MACHINE FOR MESH WELDING

WELDING MACHINE

In accordance with the welding step, the operator can adjust the upper cylinders and electrodes. Welding time and welding current are regulated and controlled by thyristors and a microcomputer timer for a more accurate electrode pitch and flawless use of electrode arrays. Water-cooled welding transformers are installed at the bottom of the welding machine and are connected to the holding electrode using flexible distribution cables, also cooled by water.



TRANSVERSE WIRE FEEDING

TRANSVERSE WIRE FEEDING

Transverse wire feeding is performed through a special automatic bar loading hopper, which is preloaded manually with the necessary number of straightened and cut wires. The automatic loading carriage for the transverse wire is equipped with a hopper for sorting, positioning and ejecting the wire.

Maximum drive load for the transverse wire: 2 ton


GRIPPING DEVICE FOR WELDED MESH

GRIPPING DEVICE FOR WELDED MESH

The device is equipped with a serve-motor and clamping handles that hang the mesh panel of the first row of transverse wire. Then the grippers pull the mesh for the remainder of one meter, based on the size of the transverse pitch.

Maximum step size: 3m at a time.



CONTROL SYSTEM

CONTROL SYSTEM

The equipment has a HMI interface that runs on a Windows system and based on a software logic controller (PLC). All parameters are set immediately on the panel. There is a system for diagnosing problems with displaying pictures to quickly eliminate and avoid excessively long stops of the machine. Feeding pushing and unloading of the longitudinal wire are driven by a servomotor with an inverter, while the welding machine itself is controlled by the S.C.R and microcomputer controller. The workflow is connected to the PLC and is displayed on the screen in a graphical form as well as fault notifications.

Trouble analysis:

  • Trouble with wire feed
  • Lack of wire
  • Error when unloading longitudinal bars
  • Error in pushing cross bars out
  • Failure to feed longitudinal bars forward
  • Lack of welding force during servo motor overload
  • Incorrect positioning
  • Abnormal pneumatic pressure
  • Overheating


DEVICE FOR WIRE TURNING AND LAYING (OPTIONAL)

DEVICE FOR WIRE LAYING

After welding, the mesh is moved by the rollers to the storage area.

Applicable sizes:
Line spacing 75 × 75 mm ~ 250 × 250 mm
Mesh width 1000 mm ~ 2600 mm
Mesh length 3500 mm ~ 6000 mm
Mesh weight 280 kg (turn)
Roller conveyor load capacity max. 4200 kg (for styling only)
Turning time less 20 sec.
Exit time 15-20 sec.
Roller conveyor length 13460 mm



Equipment operation

Welding

  • Manual feeding of longitudinal wire.
  • Accurate welding step setting (as required).
  • The automatic loading carriage for the transverse wire is equipped with a hopper for sorting, positioning and pushing the wire.
  • Depending on the wire diameter, the welding time and current can be easily adjusted.


Wire Laying

  • The finished mesh will be placed on the stacker.
  • When the required height is reached, the operator moves the accumulated meshes using a bridge crane.
  • These actions are repeated until the laying volume reaches the required limi.




FULL AUTOMATIC WELDING MACHINE R-2500D

Full Automatic Welding Machine


Main Characters

  • The machine adopts electrical and electronic synchronous control technique both welding time and cent-control welding is composed of digital and integrated electric circuit.
  • This operation is accurate, it has stable function, firm welded point and without welded tracks. Not only welding speed is fast but also it is easy to learn and operate.
  • The machine is equipped with precise equipment for weft cutting (patented) and position (patented), so the length of wefts is identical and regular, it is unnecessary to slice the side, mesh panel.
  • Drawing system adopts elastic tension link (patented) and mesh opening positioning device.
  • It is easy to regulate mesh hole and mesh opening size is rather accurate, welding aperture could adjust randomly within certain range.
  • The line wires are from the coil and the cross wires are falling automatic from the wires hopper.


Main Technical Parameters


Name Parameter
Wire diameter Ø2.0 - Ø5.0 mm
Line wire space 50 - 200 mm, adjustable
Cross wire space 50 - 200 mm, adjustable
Max. mesh width 1500 mm
Mesh length As required
Number of electrodes 31
Transformer 125 KVA × 4 sets
Welding speed 50 - 70 crosswires per minute (related to wire diameter and hole size)
Line wires form Coil from wire pay-off
Cross wires form Pre-straight and cut wires fallen by step motor
Power 380 V 50 Hz (could be customized)
Power cable cross-section 150 mm2 each phase (aluminum wire )
Welding time 10 msec ~ 100 msec
Welding voltage Adjust the welding transformer
Material Galvanized / black wire, low carbon steel wire, rebar wire. Tensile strength ≤550 N/m, Carbon Content ≤0,2%
Welding control SCR of silicon control resistance welding
Welding pressure adjust Adjust the length of beam and also the pressure of the spring
Transmission Power Brake motors
Press method By spring
Welding method synchronous control resistance
Pulling mesh method Elastic tension link
Control method Mechnical
Overall dimensions (L × W × H) 3.0 m × 2.0 m × 1.5 m
Machine weight 3 t
Power transformer in factory (provided by the client) should be bigger 160 KVA ~ 600 KVA, it is should be 50 meters max far away from the main welding equipment.


Machine Layout in Factory

Machine Layout

List of standard equipment

Components Quantity
Wire pay-off 32 pcs
Line wire straightening device 31 pcs
Wire straightening and cutting machine 1 set
Welding system 1 set
Mesh cutting machine 1 set
Electric cabinet and control system 1 set
Spare parts 1 set
Tools 1 set
User’s guide (English version) 1 set



Pictures for reference

Wire Straightening
Device
Wire Mesh
Welding Machine
Wire Straightening and Cutting Machine
Wire Straightening
and Cutting Machine
Mesh Cutting
Machine
Welding electrodes
Welding electrodes made of
conductive material



SEMI AUTOMATIC WELDING MACHINE R-2500C

Semi Automatic Welding Machine


Main parameters of welding equipment

Number of welding electrodes 31
Line wire and cross diameters 2.0 ~ 5.0 mm
Line wire space 50 ~ 200 mm, step less adjustment
Cross wire space ≥25 mm, step less adjustment
Reinforced material low carbon steel wire with carbon content ≤0,2% and tensile strength ≤550 MPa
Welding speed 40 - 60 cross bars per minute (related to wire diameter and mesh hole)
Welding transformer capacity 125 KVA × 4 sets
Welding capacity referenceØ 2-5mm,every transformer can own 8 points,min. aperture 50 × 50;
Mode of line wire feeding Pre-cut,Artificial threading
Mode of cross wire feeding Pre-cut,falling automatically by step motor


Working condition

External power supply 3-phase 380V 50Hz,distance from main control cabinet ≤50m
Control voltage DC 24V
Electric capacity Single control ≥150 KVA
Main transformer Maximum pressure drop ≤10%, Short circuit voltage ≤5%
phase cross-sectional area of power supply line 120 ~ 150 mm2 (Copper wire )
Working condition Temperature 5 ~ 40 °C, Air relative humidity ≤90% (20 °C)
Cooling system Clean, neutral to slightly alkaline (ph 7 ~ 8) water,
Water flow 2 m3/h,
Inlet water temperature 25 ~ 30 °C,
Inlet water pressure 0,15 ~ 0,3 MPa,
Refrigerating capacity 12kw



Welding Equipment Layout


Welding Equipment Layout
  1. Holding plate
  2. Main welding machine
  3. Cross wire hopper
  4. CNC drag

This drawing is for reference only. The design can be changed according to the customer's requirements.


Main equipment preparation

Main welding machine welding system 1 set
cross wire positioning device
line wire positioning device
control system
control cabinet
Optional components holding platform 1 set
stepladder 1 set
Cross wire falling cross wire 1 set
Mesh pulling device CNC drag 1 set
Round trip mesh pulling device 1 set
Auxiliary equipoment Straightening and cutting machine 2 sets
Spare parts Wear parts such as electrode units, contacts, copper connections, proximity switches, fuses, etc. 1 set




Equipment description


Main welding machine

1The main welding machine is a device to form a welding spot by welding and pressing the positioned line wire and cross wire.

Main welding machine


Cross wire hopper

Cross wire hopper is an automatic falling device suitable for a certain length of straightening and breaking material.

Cross wire hopper



CNC mesh pulling cart

CNC mesh pulling cart

The step mesh pulling mainly of composed of mesh pulling frame,mesh pulling cart and supporting mesh tube.

  • Adopt PLC programmable control system, touch screen operation interface.
  • Each functional structure is equipped with a fault detection device and has an automatic alarm shutdown function.
  • The mesh specifications and operating parameters of each mechanism are set through the touch screen interface.




Auxiliary equipment. Wire straightening and cutting machine


Layout

Layout of Wire straightening and cutting machine
  • Payoff
  • Safety shelf
  • Main straightening machine
  • Wire falling runway
The detailed installation size and layout of the equipment will not be provided until the contract and all its machine parameters are determined.


Main straightening machine

Main straightening machine

The main straightening machine is composed of a twisting device, a straightening device, a cutting device and a power transmission mechanism.


Falling runway

Falling runway

The wire falling runway consists of a straight wire runway, a length positioning device,and loading materials.



Payoff
Payoff
Safety shelf
Safety shelf
Control system
Control system
Control system
Control system



EQUIPMENT FOR WELDED MESH PRODUCTION RGA SERIES


The design of the equipment for production of welded mesh and metal reinforcement frames of RGA series does not concede to the equipment of such leading foreign manufacturers as Clifford (South Africa), Schnell (Italy), AWM (Italy). At manufacturing of this equipment accessories of leading world manufacturers are widely used. This line of the equipment provides a full cycle of manufacture of a welded grid with high degree of automation of processes, high operational reliability, fast and convenient adjustment.


welded mesh production


Composition of the welded mesh production line

Composition of the welded mesh production line
  • Longitudinal bar feed module.
  • Accumulation unit.
  • Welding portal (the main machine of the line, which is responsible for the welding of bars)..
  • Cross bar feed module.
  • Mesh longitudinal movement module (roller conveyor).
  • Option. Guillotine scissors.
  • Option. Stacking unit.
  • Option. Mesh packer.
  • Option. Wire unwinder.


Mesh material - low-carbon wire, stainless steel wire, reinforcing wire, galvanized wire; a straightening and cutting machine is required for the production of measuring bars.


Specification of mesh welding equipment

Model Length of longitudinal bars, mm Length of cross bars, mm Wire diameter, mm Line wire space, mm Cross wire pitch, mm
RGA-125 2000~6000 1000~2400 Ø3~6 ≥100(50) ≥50
RGA-200 2000~6000 1000~2400 Ø6~10 ≥100(50) ≥50
RGA-300 2000~6000 1000~2400 Ø6~12 ≥100(50) ≥50


Energy consumption of equipment for welded mesh production

Number of welding transformers 9 pcs
Transformer power based on 50% load cycle 150 KVA
Nominal secondary current 22 KA
Secondary voltage 9 V
Number of cylinders 30 pcs
Compressor power 50 hp, 500 kg/sm2
Distance between electrodes 95 mm
Power supply voltage 3-phase 380 V 50 Hz±10%
Cross section of power supply cable 300 mm2 for one phase
Fuses with delayed actuation 1600 A
Air pressure 5~8 kg/sm2
Water consumption for cooling 250 l/min.
Water temperature room temperature ±3°C


Brief description of mesh welding equipment

Previously cut off cross bars by the straightening machine are fed by the operator to the hopper of the cross bar feed module by means of a girder crane or hoist.

Longitudinal measuring bars are charged directly into the longitudinal bar feed module. This reduces the downtime of the welding machine by loading the bars in the feed position to the welding portal during the production of the previous mesh.

After the start command is given, the mesh starts welding on the welding portal. The mesh is then moved all the way through with the servo drive of the longitudinal module. The baling module stacks the mesh in a stack.

A straightening and cutting machine is required for the production of measuring bars.


Longitudinal bar feed module

The longitudinal bar loading module allows the loading of bars (maximum 60 pcs) and their feeding to the welding portal during the production of the previous mesh, thus reducing the downtime of the line, increasing the productivity on average by 1.5-2 times.

The longitudinal bar is inserted by the operator manually into the guide bushings. The longitudinal bars are moved to the welding portal by means of a carriage. Wire sensors make it possible to exclude the possibility of manufacturing defective wire mesh.


Accumulation unit

The equipment has 2 sets of wire feeders. The first set is driven by the motor, directing the longitudinal bars into the storage bin (maximum 60 longitudinal bars). The second set is driven by a servo-driven roller conveyor to transfer the longitudinal bars to the welding portal.



Welding portal with cross bar feed module

The welding portal is the main machine of the line. The maximum line capacity, the diameter of the bars to be welded, the geometric dimensions and the mesh design are determined by the characteristics of the welding portal.

The welding gantry is equipped with a cross bar feed module (with a 2 ton hopper), which is fed automatically during welding.

Cubic shaped electrodes made of special material (base - copper, reinforcement additives - TiC, TiO2) allow to increase their service life due to repeated use of faces.

The productivity of the welding portal of 60-80 cross bars per minute (depending on the diameter of the bar), welding speed is 0.5-1.2 seconds.

An air compressor is not included in the basic scope of delivery.



Control system

The welding equipment control system includes a Programmable Logic Controller and an operator panel with HMI interface. An integrated fault diagnosis system is available. Welding portal operating modes are controlled by a microcomputer using a thyristor converter.


Water cooling system (optional)

For efficient operation of the welding transformer it is necessary to use a water cooling system of the flowing or closed-loop type. The system consists of the following main components: frame, pump, radiator, control unit, water tank.



Guillotine shears (optional)

The hydraulic knife automatically cuts the welded mesh to length.

Knife material: SKD11
The range of diameters of the workpiece to be cut: Ø4.0-8.0 mm
Cutting speed: 45 cuts/min.
Cut-off mesh width: max. 3100 mm
Hydraulic motor power: 20 hp



Stacking unit (optional)

The unit performs a turn of the welded mesh and transportation to the storage area.

Roller conveyor length: 13 meters
Interval: 75×75 mm - 250×250 mm
Mesh width: 1500 mm - 3100 mm
Mesh length: 3500 mm - 6000 mm
Mesh weight: 280 kg (turn)
Roller table load capacity: max. 4200 kg (only for stacking)
Turnaround time: < 20 sec.
Unloading time of the finished product: 15-20 sec.


Wire unwinder (optional)

The wire unwinder is used when the initial workpiece for feeding longitudinal bars is wire in coils. Capacity - 60 pcs. The wire unwinder is equipped with a motor and a wire feed speed inverter.



Stacker (option)

The main task of the bundling and rolling module is to free the welding portal from the finished mesh. The baler is located directly below the longitudinal transport module, where the stack of mesh is formed. At the end of the production process, the next baler blade is lowered and stacked into a stack.

Roller conveyor length 7 meters
Mesh interval: 100×100 mm – 250×250 mm
Mesh width: 2400 mm – 3100 mm
Mesh length: 3000 mm – 6000 mm
Height of the tied grid: 400 mm
Bonding speed: < 35 sec/stacking kit
Time to unload the finished product: 15-20 sec.


Mesh longitudinal movement module (roller conveyor)

The module of longitudinal mesh movement through the welding portal, because of the use of servo drive, allows to produce mesh with variable pitch of cells. The spacing between the cross bars is set via the control panel and can be changed smoothly.





VIDEO OF MESH WELDING EQUIPMENT OPERATION

Semi Automatic Welding Machine

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Full Automatic Wire Mesh Welding Machine

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How mesh welding equipment works



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