Machinery & Automation
Composite Rebar Manufacturing Machine — Deep Modernization & Patent
The Challenge
The client — a building materials manufacturer — purchased a composite rebar machine from China that proved unreliable with frequent breakdowns. The machine required deep modernization to achieve stable production. Additionally the client needed complete manufacturing drawings to produce multiple machines independently without relying on the Chinese supplier.
Our Solution
Performed complete redesign of key systems: glass fiber impregnation unit, armature winding unit (patented), cooling unit, segment unit with counters, and packaging unit. Designed a new broach unit for pulling reinforcement bars over 22mm diameter with pneumatic clamp. The new winding unit — patented by Russian supervisory authorities — is simple, reliable and prevents thread tangling. Full manufacturing drawings and diagrams developed for independent production.
Scope of Work
Deep machine modernization, patented winding unit design, full engineering documentation for serial production, procurement supervision, subcontractor management, production floor organization, quality control, equipment certification, personnel training, one year of operational monitoring and maintenance support.
Result
Machine achieved stable reliable production output. Client received complete documentation package for independent manufacturing. All new equipment certified by supervisory authorities. Personnel fully trained on new systems. Author's supervision maintained throughout the first year of operation.