Filmedia® supplies a full range of advanced filter cage making machines designed for the production of high-quality filter cages. With a wide variety of machine types and comprehensive forming functions, our equipment can meet the manufacturing requirements of different filter cage structures, dimensions, and customized designs.
The machines feature stable operation, high production efficiency, precise forming performance, and easy operation, making them suitable for producing industrial dust collector filter cages for cement plants, steel plants, power stations, waste incineration systems, and other filtration industries.
From standard round filter cages to special-shaped and customized cage designs, Filmedia® provides reliable and efficient manufacturing solutions to help customers improve production quality, reduce labor costs, and enhance overall manufacturing efficiency.
Description
01. Filter Cage Welding Machine (CBW-90-V2)
Advantages (Compared with old version)
1. Cylinder Speed
Pneumatic circuit design is optimized with fast cylinder speed, greatly reducing weld detachment caused by slow response of pneumatic circuit and solenoid valves.
The internal air pipeline adopts Φ30 aluminum pipe for large air supply volume.
Valve-integrated cylinders are adopted to shorten the pneumatic circuit.
2. Operability
No need to plug and unplug air pipes inside the machine.
The number of air pipes is reduced with external connection, making operation simple and easy.
3. Stepless Adjustable Mandrel (Standard)
Standard equipped with stepless adjustable mandrel to realize diversified adjustment of cage outer diameter. No need to purchase new molds when changing the outer diameter of ribbed filter cages.
4. Expanding Electrode System (Optional)
It automatically compensates electrode wear. The support ring is welded under tension with good contact with the electrode, effectively reducing weld detachment.
5. Manual Lifting Rail Bracket (Optional)
6. Solenoid Valve Heating System (Optional)
The solenoid valve heating system solves the problem of slow response of solenoid valves due to freezing in cold weather.
Basic Parameters
| Voltage | 2-phase 380V; customized |
| Transformer Design Capacity | 80KVA |
| Number of Transformers | 2 sets |
| Instantaneous power under synchronous working mode welding | 36KVA |
| Instantaneous power under time-sharing working mode welding | 18KVA |
| Number of Weldable Vertical Wires | 6, 8, 10, 12, 14, 16, 18, 20, 22, 24 |
| Distance Between Rings | Ring spacing can be set arbitrarily. |
| Filter Cage Outer Diameter | 100-200mm |
| Rail Length | 7.5m, 9m, customized |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 300 L/min |
Machine Features and Advantages
1. Adopts newly designed integrated body with built-in electric cabinet, reducing plugging and unplugging of cable connectors for more convenient operation.
2. The human-machine interface is simple and user-friendly. The machine is controlled by touch screen with multi-language versions, easy for operators of different countries and languages to master.
3. It realizes welding spot quality control and monitoring. The equipment is equipped with an active learning function to identify welding spots with abnormal fastening strength and automatically adjust the welding current for repair welding.
4. For materials of different properties, besides the welding current magnitude, the current waveform is more critical and must be differentiated. The material selection function enables optimal welding results for various materials.
5. Stepper motor driven cage pulling; each ring pitch can be set arbitrarily.
6. When the power grid capacity is insufficient, the machine can be switched to time-sharing mode to keep the welding quality unaffected.
1. High welding speed. For example, when welding a 12-rib filter cage, it takes only 0.18 seconds to weld one ring, with ring pitch accuracy of 0.1 mm and cage pulling speed of 0.4 m/s.
2. When the set ring pitch is too small, the machine can automatically enlarge the pitch for easy ring placement, and restore to the correct pitch for welding after the ring is in place.
02. Filter Cage Welding Machine (CW-90)
The latest filter cage welding machine integrates the welding of cage body, top collar and bottom collar into one unit.
Machine Features and Advantages
- One single machine can weld the filter cage body, top support and bottom support, improving production efficiency and reducing labor costs.
- It features a simple and user-friendly HMI. The machine adopts touch screen control with multi-language versions, making it easy for operators from different countries to operate proficiently.
- The machine boasts high reliability and extremely stable performance.
- It realizes welding spot quality control and monitoring. Equipped with an active learning function, the machine can identify welding points with abnormal bonding strength and automatically adjust the welding current for repair welding.
- For different materials, apart from welding current magnitude, the current waveform is more critical and needs to be set differently. The Material Selection function ensures optimal welding results for all types of materials.
- Cage pulling driven by stepper motor; each ring pitch can be set freely. A single filter cage can accommodate up to 54 support rings, with two pulling speed options: High and Medium.
- The rail (standard length: 7.5 meters) is connected to the main unit at the front end. The newly upgraded ball linear slide rail effectively guarantees the straightness of the filter cage and offers long service life.
- The pneumatic structure designed by a professional institute ensures fast and responsive cylinder movement.
- The panel is integrally machined from 25 mm steel plate, ensuring all welding cylinders are on the same plane and accurately aligned with the cage axis, so as to guarantee the straightness of the filter cage.
- When the grid power capacity is insufficient, the machine can be switched to Time-Sharing Mode to keep welding quality unaffected.
- High welding speed: for 12-rib filter cages, only 0.18 seconds is required for welding one ring, with ring pitch accuracy of 0.1 mm and cage pulling speed of 0.4 m/s.
- Built-in ring pitch automatic compensation function: when the set pitch is too small, the machine automatically widens the pitch for easy ring placement, then reverts to the original set pitch for welding after placement.
Basic Parameters
| Voltage | 2-phase 380V; customized |
| Transformer Design Capacity | 160KVA |
| Number of Transformers | 2 sets |
| Instantaneous power under synchronous working mode welding | 36KVA |
| Instantaneous power under time-sharing working mode welding | 18KVA |
| Number of Weldable Vertical Wires | 6, 8, 10, 12, 14, 16, 18, 20, 22, 24 |
| Distance Between Rings | Ring spacing can be set arbitrarily. |
| Filter Cage Outer Diameter | 100-200mm |
| Rail Length | 7.5m, 9m, customized |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 300 L/min |
03. Ring Making Machine (R-B-W-6-300)
Basic Parameters
| Voltage | 2-phase 380V; customized |
| Transformer Design Capacity | 40KVA |
| Instantaneous power when making rings | 2KVA |
| Instantaneous power when welding rings | 15KVA (4mm thickness wire) |
| Standard Ring Diameter | 70~300mm |
| Ring Diameter | 50~600mm |
| Wire Diameter | 2~5mm |
| Production Speed | 150pcs /hour (dia. 150mm) |
| Cooling Method | Natural Cooling |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 250 L/min |
Machine Features and Advantages
- High Precision: Adopts intelligent S-curve speed profile, together with a closed-loop ring diameter stepping control system composed of rotary encoder and motor. It ensures the circumference error of steel wire rings is within 0.5 mm, thoroughly solving the ring diameter accuracy problem of traditional mechanical and flattening machines.
- High Reliability: Wire feeding is directly driven by two motors. The machine has no gears, pulleys or any wear-prone parts that would cause accuracy degradation.
- Easy Operation: Ring size is adjusted by handwheel with scale ruler assistance; all other parameters can be set on the touch screen.
- Fully Automatic Operation: Automatic welding with no manual intervention required during operation.
- Wide Compatibility: The multi-functional welding system is suitable for ring forming and butt welding of low-carbon, medium-carbon and high-carbon steel, spring steel and galvanized wire. Equipped with an optional TIG welding unit, it can realize automatic ring forming and butt welding of stainless steel and aluminum alloy.
- Easy Maintenance: Universal welding electrodes are adopted, with no need to replace electrodes for different ring sizes. There is no hydraulic system inside the machine. Long-service-life electrodes and cutters are used to lower maintenance costs.
- High Intelligence: The HMI is highly functional. All moving parts are monitored by sensors with protection functions, avoiding major losses caused by misoperation. Real-time running code is displayed, allowing easy commissioning, operation and machine diagnosis directly via the touch screen.
04. Top Collar Welder (TCW-90)
05. Venturi Tube Welding Machine (VTW-90)
Machine Features and Advantages
- Specially designed integrated pressurizing cylinder ensures stable pressurization, rapid response and high welding speed.
- Integrated machine frame with high structural rigidity.
- The top support positioning flange and adjustable bracket ensure the perpendicularity between the top support and the central axis of the filter cage.The top support welding unit is also applicable to the welding of connecting rings for multi-section filter cages.
- Horizontal welding design, suitable for manufacturing filter cages of any length, complete with supporting brackets.
Basic Parameters
| Machine Code | TCW-90 | BPW-90 | VTW-90 |
| Rated Input Voltage | 2-phrase 380V (50HZ); customized | ||
| Transformer Capacity | 80KVA | 80KVA | 80KVA |
| Working Load | About 35KVA | ||
| Air Consumption | 100 | 200 | 80 |
| Cooling Method | Water Cooling | ||
06. Ring Butt Welder (MS-Ring-W-50)
Advantages
- This equipment is a resistance welding machine, suitable for butt welding of low-carbon steel wire.
- High welding speed; skilled operators can weld up to 8,000 rings per shift.
- Small heat-affected zone of approximately 3~4 mm, ideal for welding galvanized wire.
Basic Parameters
| Voltage | 2-phase 380V (50HZ); customized |
| Transformer Design Capacity | 40KVA |
| Working Load | 15KVA |
| Wire Diameter | 2.5~6mm |
| Cooling Method | Natural Cooling |
| Air Consumption | 150 L/min |
07. SS Ring Argon Arc Welder (SS-Ring-W)
- Welding Principle: TIG welding; suitable for butt welding of stainless steel wire.
- Advantages: Strong and smooth weld joints.
Basic Parameters
| Rated Input Voltage | Single-phase 220V or 380V (50Hz); customized |
| Welding Power | 12KVA |
| Max. Output Current | 300A |
| Wire Thickness | 2.5~6mm |
| Cooling Method | Natural Cooling |
| Compressed Air Consumption | About 150 L/min |
| Argon Consumption | 5 L/min |
08. High-Speed Wire Straightening Machine (WS-4-100)
Basic Parameters
| Input Voltage | 380V 3P 50/60Hz |
| Power Capacity | 12KVA |
| Power Consumption | 5~12KWH |
| Weight | 1200KGS |
| Wire Thickness | 2~6mm |
| Cutting Length | 50~8000mm |
| Length Accuracy | ±1mm |
| Pulling Speed | 15~100m/min |
| Applicable Materials | Wire rods with tensile strength of 350~1200 MPa.
Such as low carbon steel, medium carbon steel, high carbon steel, alloy steel, stainless steel and galvanized wire. |
09. Entry-Level Wire Straightening Machine (WS-4-25)
Basic Parameters
| Rated Input Voltage | 380V 3P |
| Rated Power | 4KVA |
| Feeding Speed | 25m/min |
| Wire Thickness | 2.8~5mm |
| Length Range | 500~8000mm |
10. Plus Top Collar Welder (P-TCW-90)
Working Principle:
Position with the mounting reference plane of the cage upper support. Lock the upper support and weld at 4 points to ensure the perpendicularity between the upper support mounting surface and the cage axis.
Then rotate the cage; the main machine automatically completes welding of the remaining points.
The cage fixed-length device ensures consistent cage length of each cage.
Basic Parameters
| Rated Input Voltage | 2-phase 380V; customized |
| Rated Frequency | 50/60HZ |
| Instantaneous Power During Welding | About 35KVA |
| Transformer Design Capacity | 80KVA |
| Number of Transformers | 1 set |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 100 L/min |
| Cooling Method | Water Cooling |
| Weight | About 600KGS |
11. Linking Ring welder (LRW-90)
- Suitable for multi-section cages connected by twist-lock and snap-fit methods to ensure the straightness of the cages.
- Fully guarantee the perpendicularity between the joint (connecting ring) plane and the central axis of the cage.
- Complete five-point positioning welding at the right station first, then weld the remaining points at the left station.
Basic Parameters
| Rated Input Voltage | 2-phase 380V; customized |
| Rated Frequency | 50/60HZ |
| Instantaneous Power During Welding | About 15KVA (Snap-fit connection)
About 35KVA (Twist-lock connection) |
| Transformer Design Capacity | 80KVA |
| Number of Transformers | 1 set |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 100 L/min |
| Cooling Method | Natural Cooling |
| Weight | About 600KGS |
12. Pneumatic Bottom Cap Crimper (BP-100-2)
13. Wire Bending Machine-L (WB-L)
14. Wire Bending Machine-M (WN-M)
Basic Parameters
| Machine Code | BP-100-2 | WB-L | WN-M |
| Rated Input Voltage | Single-phrase 220V; customized | ||
| Air Source Pressure | 0.6-0.8MPa | ||
| Air Consumption | 150L/min | 100L/min | 150L/min |
15. Flat Type Filter Cage Welding Machine (FCW-90)
Advantages:
- Gear transmission with high ring spacing accuracy.
- Adopts linear guide rails; the trolley runs flexibly and ensures high straightness of the cage.
- During welding, the rings are automatically locked to ensure the ring plane is perpendicular to the central axis of the cage.
- Each ring spacing can be set by programming. Equipped with imported servo motors and precision planetary gear reducers. The cage pulling system consists of stepping motors and racks, featuring high ring spacing accuracy and no cumulative positioning error. The cage pulling speed is 0.4 m/s, making it highly suitable for multi-section cages with multiple ring spacing dimensions.
Basic Parameters
| Rated Input Voltage | 2-phase 380V; customized |
| Rated Frequency | 50/60HZ |
| Instantaneous power under synchronous working mode welding | 36KVA |
| Instantaneous power under time-sharing working mode welding | 18KVA |
| Transformer Design Capacity | 80KVA |
| Number of Transformers | 2 sets |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 300 L/min |
| Cooling Method | Natural Cooling |
| Weight | About 1300KGS |
16. Versatile Flat Cage Welding Machine (VFBW-90)
17. Flat Cage Top Collar Welder With Verticality Assurance (FCTW-90)
Advantage:
Easy to operate. All welding can be completed in one clamping setup. Equipped with upper support locking function to ensure the perpendicularity between the bag cage upper support and the central axis.
Basic Parameters
| Rated Input Voltage | 2-phase 380V; customized |
| Rated Frequency | 50/60HZ |
| Instantaneous power when welding | 20KVA |
| Transformer Design Capacity | 80KVA |
| Number of Transformers | 1 set |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 300 L/min |
| Cooling Method | Natural Cooling |
| Weight | About 600KGS |
18. Flat Cage Guiding part Welder (FCGW-90)
Basic Parameters
| Rated Input Voltage | 2-phase 380V; customized |
| Rated Frequency | 50/60HZ |
| Instantaneous power when welding | 20KVA |
| Transformer Design Capacity | 80KVA |
| Number of Transformers | 1 set |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 300 L/min |
| Cooling Method | Natural Cooling |
| Weight | About 600KGS |
19. Flat Ring Making Machine (FRMM-540)
Advantage:
By replacing the ring forming wheel spare parts, the ring size can be adjusted.
The ring circumference is stable with excellent consistency.
Basic Parameters
| Rated Input Voltage | Single-phase 380V; customized |
| Rated Frequency | 50/60HZ |
| Instantaneous power when welding | 4KVA |
| Air Source Pressure | 0.6~0.8MPa |
| Air Consumption | 100 L/min |
| Ring Size | Min. 40*130mm
Max. 80*380mm |
| Weight | About 350KGS |
