HLY-OP-02: CNC Rebar Cage Welder Touchscreen Programming & Resistance Welding SOP

1. HMI Touchscreen Recipe Programming

Navigate to "Recipe Setup", load target standard profile (e.g., DN1000-GB2.5M).

Input dimensional parameters:

- Total cage length (e.g., 2480 mm);
- Rebar quantity and indexing pitch (e.g., 24 bars at 15° spacing);
- Bell/spigot end densification zone length (set to 300 mm);
- Dense zone helical pitch (set to 40 mm);
- Middle standard pitch (set to 100 mm or 120 mm);
- End closed weld loops (set to 2.5 complete turns at each end).

2. Resistance Spot Welding Calibration

Welding Current %: Adjust SCR trigger firing angle according to rebar gauge (Φ5–Φ10 mm), typically 45%–70%.

Weld Duration Cycles: Set weld current time to 3–6 AC cycles; hold squeeze time to 2 cycles.

Electrode Squeeze Pressure: Maintain regulator at 0.55 MPa, ensuring cross-weld indentation depth reaches 20%–25% of longitudinal wire diameter.

3. Production Monitoring & Recovery

Inspect copper weld wheel tread. If localized pitting appears, stone the contact face smooth.

If rebar coil snags or breaks, hit "Pause", clear obstruction, and press "Resume" to maintain pitch continuity.