Quality control of incoming materials; storage of tubes and drawn material in a large automated underground warehouse.An important raw material accumulation buffer allows Tecnorulli to absorb procurement market turbulence, guaranteeing customers reliable delivery times and consistent product quality.

Automatic loading of 4 cutting lines.From the underground warehouse, a system with 3 automated stacker cranes constantly feeds the 4 cutting lines using FIFO logic, under the supervision of a control system that optimises production time as according to customer delivery requirements.

Automatic cutting of tubes (ø 12 ÷ ø 244mm) and drawn material (ø 7 ÷ 60mm).The phase of cutting to size and pre-machining of tubes takes place on an island equipped with several automated cutting heads, end cutting units and boring machines.

Machining of end cuts and bores of tubes performed in line.End cutting units and boring machines pre-machine the tubes with centesimal precision, facilitating the subsequent phases of welding and assembly.

Subdivision of cut tubes according to different production and delivery criteria.Our customers’ orders are routed to different welding lines and assembly islands according to delivery priority and optimisation/reduction of production times.

Automatic feeding of welding lines.To ensure an interruption-free welding process, a computerised handling system feeds the machines with pre-machined tubes and semi-finished products.

Automated welding of rollers with instantaneous control of head concentricity.Roller jackets are made on several automated lines; following welding, each roller is checked for concentricity of the bearing housing bottoms, gears and flanges relative to the tube, as a guarantee of a finished product free from defects.

Deep penetration welding for drums with thick tubes.The flanges of drums intended for the most demanding working conditions and for the most efficient transport systems are welded by certified operators, using specific parameters depending on the composition and thickness of the materials used.

Shaft machining.On the shaft of rollers and drums, four transfer systems realise the machine work of end cutting, milling, drilling, threading, seeger grooving, grinding, diameter reduction at the ends, at a rate of less than 15″ for each piece.

Drum turning.Using control lathes and self-learning, turning profiles to design can be produced with centesimal tolerances on drums with a length up to 3300 mm.

Automated assembly of rollers with straightness control in output.The phase of assembly of jackets with the shaft and insertion of bearings and seal kits takes place on five different subservient lines, also using an anthropomorphic robot and equipped with a system that controls the straightness and correctness of the axial clearance on each roller leaving the machine.

Cladding with PVC sheaths or rubber sleeves. The PVC sheaths and rubber sleeves are fitted using a compressed air system, which ensures a perfect adherence between the cladding and the roller tube.

Hot rubberising.On the customer’s request, roller and drum jackets can be clad with natural rubber, synthetic rubber, silicone, polyurethane, etc., both with a smooth surface (machined or ground) and with a surface machined with rhomboidal pressings.

Grinding of drums hubs.Where the drums are intended for very high performance applications (high speed, closely spaced motor ignition and switching off frequencies, etc.), the ends of the hubs are ground with millesimal tolerances.

Straightening.All rollers and drums with an eccentricity greater than that required for the specific application of the customer are straightened and brought back within very narrow tolerances.

Fitting of rubber rings.An automated system can place the rings on the tube in any position required by the customer.

Quality control in output.Before being packaged, the rollers of each order are controlled using statistical criteria, so that the customer always receives a product in line with what was commissioned.

Storage of finished products in automated warehouse.The finished products waiting to be shipped are stored in a large capacity automated warehouse, from which they are withdrawn only at the time of collection by the customer.