Jinchun Cage Frame Production Solution: Full-Process Automation Leading Industry Innovation

1. Introduction: Defining the New Standard for Cage Frame Intelligent Manufacturing

As a leader in the metal processing industry, Jinchun Technology has been deeply involved in the development of industrial automation equipment for over a decade. In response to the efficiency bottlenecks and quality issues faced during cage frame production, we have launched a full-process intelligent production solution. This solution is based on six core pieces of equipment, covering the entire lifecycle from wire material straightening to final product welding. It enables customers to achieve high-efficiency, stable production of 1000 cage frames per day, setting a new benchmark in the industry.

 

2. Core Equipment Matrix: Precisely Empowering Each Step of the Process

1. XLC-1-6 Coil Making Machine — The Precision Forming Starting Point

Core Parameters: 

Suitable Wire Diameter: Φ1mm ~ Φ6mm 

Coil Range: Φ55mm ~ Φ850mm 

Cutting Precision: Circumference ±0.50mm 

Production Efficiency: 20~40m/min 

Process Value:

The servo motor precisely controls wire tension, enabling rapid forming of circular coils with high consistency. This provides standardized components for subsequent welding.

 

2. XLC 35kW Pneumatic Spot Welder — Core Support for Stable Welding

Technical Highlights: 

35kW high-power output to meet high-strength welding demands 

Water-cooling system ensures operational stability 

Compatible with a two-phase 50Hz power supply 

Application:

Completes preliminary welding of circles and straight lines, ensuring weld strength ≥90% of base material, and eliminating potential loosening risks.

 

3. XLC 2.5-5 Straightening Machine — The Quality Foundation for Wire Processing

Key Performance:

Straightening Range: Wire diameters from 2.5mm to 5mm 

Maximum Fixed Length: 2000mm 

Straightening Efficiency: 20m/min 

Visual Advantage:

Multiple straightening rollers eliminate wire bending deformation, ensuring a linearity error of less than 0.3mm for subsequent processes.

 

4. Environmental Dust Removal Cage Frame Welder — Industry Standard for Clean Production

Customized Design: 

Supports cage frame diameters from 100mm to 200mm 

Flexible adjustment for 8-24 longitudinal ribs 

Integrated pulse dust removal system with a filtration efficiency of 99.5% 

Process Breakthrough:

Enables the automated welding of both straight sections and ring structures, with uniform, aesthetically pleasing weld seams that meet environmental emission standards.

 

5. Upper and Lower Support Welders — Ultimate Support for 3D Welding

Dual Machine Coordination Strategy: 

Upper Support Welder (50kW power): Uses pneumatic pressure (0.5-0.7Mpa) to strengthen the top support part of the cage frame. 

Lower Support Welder: Specializes in the precision welding of the bottom tray, ensuring balanced weight distribution across the structure. 

Collaborative Efficiency:

Synchronized dual-machine operation achieves a welding speed of 15m/min, improving tensile strength by 40%.

 

3. Process Flow: Full-Link Automation from Raw Material to Finished Product

Step 1: Wire Preprocessing

The straightening machine ensures wire straightness with a deviation of less than 0.3mm through straightening and length cutting. 

Step 2: Circle Forming

The coil-making machine forms high-precision circular components according to set parameters, with a product qualification rate of over 99%. 

Step 3: Main Body Welding

The spot welder completes preliminary welding of circles and straight lines, with adjustable weld point density. 

Step 4: 3D Welding

The upper and lower support welders work together to reinforce the cage frame’s top and bottom structures. 

Step 5: Final Quality Inspection

A laser scanner performs 360° weld seam inspection, with a defect rate controlled at less than 0.5%.

 

4. Technical Advantages: Four Core Engines for Cost Reduction and Efficiency Improvement

Modular Design

The six core machines operate independently yet are interconnected. The production line layout can be adjusted flexibly to save 40% of installation space. 

Intelligent Control System

Equipped with a PLC touch screen and MES interface, it supports remote monitoring and real-time parameter adjustments, increasing individual productivity by 3 times. 

Green Production System

The pneumatic spot welder’s water-cooling system and the pulse dust removal system ensure a dust-free operation, reducing annual maintenance costs by 20%. 

Material Compatibility

The system supports over 20 types of wire materials, including carbon steel, stainless steel, copper, and aluminum, meeting the diverse needs of different industries.

 

5. Investment Return Model: Low-Cost, High-Profit Golden Choice

Taking the production of 1000 cage frames per day as an example: 

Total Investment: Approximately 2.6 million RMB (including taxes and installation fees) 

Unit Cost:

Electricity Consumption: 1200 RMB/day 

Welding Wire Consumables: 800 RMB/day 

Revenue Estimate:

At a market price of 280 RMB per set, daily revenue reaches 280,000 RMB, with a payback period of approximately 9-12 months.

 

6. Service Commitment: Jinchun Technology One-Stop Support

Turnkey Project: Full support from equipment installation to personnel training, with 7×24-hour technical responses. 

Lifetime Warranty System: Core components come with a 3-year warranty, and software systems are upgraded for free to the latest version. 

Customized Development: Special welding modes and process packages can be developed according to customer needs.

 

7. Conclusion: Smart Manufacturing, Partnering with Jinchun for a Bright Future

This solution, through the coordinated innovation of six core pieces of equipment, brings traditional cage frame production into a new era of intelligent, refined, and green manufacturing. Jinchun Technology will continue to be committed to making "Chinese manufacturing more reliable" and providing globally competitive industrial solutions. 

Contact Jinchun Mechanical Equipment Co.,Ltd

Tel: +86 15015830219 

Email: [email protected]

Website: www.jinchunxlc.com