Berco Complete Track Systems
Transcription
Berco Complete Track Systems
Berco Complete Track Systems The Widest Undercarriage Choice The n. 1 in Undercarriage 6,000,000 1,300,000 180,000 380,000 250,000 12,500 Track Shoes Rollers Track Chains Idlers and Sprockets Tons of product Containers of product MOVING YOUR BUSINESS AHEAD 4BTS COMPLETE TRACK SYSTEMS A Company of ThyssenKrupp Group BERCO S.p.A. MOVING YOUR BUSINESS AHEAD WE CARE YOUR BEST UNDERCARRIAGE VALUE CUSTOMER SERVICE Since 1920 Berco has offered an innovative, reliable and economical solution to any undercarriage need. Whether for the original equipment manufacturers (OEM) or the aftermarket, for a special machine or a miniexcavator, for a bulldozer or a mining excavator, Berco can offer you the right answer to your specific requirement. We have a large dealer network covering more than 90 countries in the world. They have been in business for decades, they know the business and they know it from their customers’ point of view. They understand customers’ needs and they know that their success is tied to their customers’ successes. Superior engineering, innovative technology, comprehensive know how and state-of-the-art manufacturing guarantee the total quality of the products and services offered to you. “Original Equipment Quality, Aftermarket Value” AN EXPERT PARTNER YOU CAN RELY ON Custom made solutions and project engineering support is available upon request. Our team of engineers can help you choose or design the most effective and efficient solution to your specific undercarriage need. They can help you reduce development and engineering time, tooling expenses and facility costs, while adding value to your business. “Berco, The choice of the leading OEMs” All products shown in this document originate from Berco exclusively. Any references to Caterpillar (the Caterpillar word signs) are mentioned to communicate that the aforementioned products are only suitable for Caterpillar machines with the corresponding model designation. We support our dealers with our professional sales force. We train them, and provide them with the right marketing tools and advanced technological systems. We have developed a computer based integrated system BOPIS (Berco Online Product Information System) enabling a dealer technician to use a laptop computer from the field to consult our database and easily find the right answer. We back you, wherever you are. We work with our dealers to establish a parts and service presence near you, in order to always have the right product at the right time in the right place. It is customer satisfaction that has built our Berco Track Record. CUSTOMER SATISFACTION Considering that more than 50% of your maintenance costs will go into maintaining the undercarriage, it is not surprising that Berco represents the best choice when the time comes for the replacement. And the best choice is confirmed by the large number of Satisfied Customers that Keep Choosing Berco LEADERSHIP IN ENVIRONMENTAL DEVELOPMENT Not only do we care about our customers supplying quality products manufactured under ISO 9001:2000 certified processes, but, also, we care about the Environment. Since Jan 2000 Berco is ISO 14001 certified and has adopted Environmental Procedures throughout the entire manufacturing process. We have an Environmental Strategy and we continuously check on the progress made toward the set objectives. Getting More out of Less. Reduction of energy consumption, improved use of materials and minimization of waste, allows for a lower impact on the environment. We have given preference to environmentally friendly transportation like trains and boats and we have begun redesigning our packaging in order to use recyclable materials. We have changed our painting processes and now use environmentally friendly water-based paint, with a reduction in the amount of pollutant emissions. We have adopted a closed loop cooling system that reuses the water from our heat treatment processes instead of emitting it into the environment. ISO 9001 - ISO 14001 COMPLETE TRACK SYSTEMS SYSTEMS TAILORED TO CUSTOMER NEEDS In order to respond to the growing interest shown by OEMs in “turnkey” solutions, Berco now offers a series of complete undercarriage systems for a wide range of applications, such as pavers, drilling machines, road planers, rice combine harvesters, etc… This new range of products is confirmation of Berco’s ability to provide integrated solutions, working together with the customer from the initial design stage right through to the supply of the fully assembled undercarriage - the “complete track system” - with undercarriage components, frame, hydraulics and transmission systems, ready for direct installation on the machines on the manufacturer’s assembly line. Berco is proud of the services it can offer its customers, which include solutions perfectly tailored to customers’ needs and specifications, flexible engineering to achieve the best undercarriage solution quickly and efficiently and comprehensive product support that accompanies customers from the design stage right through to installation in the field. A SPECIAL PRODUCTION UNIT FOR COMPLETE TRACK SYSTEMS With this goal in mind Berco has developed a specific production plant to guarantee the manufacturing capacity necessary to meet customers’ needs - in terms both of quality and quantity. A new Berco division has been organized to engineer, manufacture and assemble a wide variety of different complete track systems: working according to the specifications of both the design department and the customer (coengineering), the products made by this unit (specialized in the production of track systems complete with undercarriage components, frame, reduction gear, etc…) are superb. The Complete Track Systems production unit not only specializes in the manufacture and assembly of complete undercarriage systems (for many applications and many machine types and sizes), but is also capable of supplying welded parts for earth moving equipment (i.e. excavator arms and booms, loader arms, drums, etc…). The new Berco Track System division is capable of providing the customer with a complete manufacturing solution, using the combined resources of its three factories. CNC machining centers (workpieces up to 4 meters long), CNC robotic welding systems, manual welding cells and a wealth of experience in the field are the key factors in ensuring high levels of quality and capability. BERCO, THE COMPETENT LEADER YOU CAN RELY ON COMPLETE TRACK SYSTEM Designing the right undercarriage solution is a very complex task. A lot of variables and constraints have to be taken into account, especially when the application is not standard and requires ad-hoc solutions and skills. Being sure to create the cheapest and, at the same time, most reliable undercarriage class for a given application is not as simple as it may appear: track rollers have to be scaled to be strong enough both to withstand concentrated impulsive loads and support the machine in movement; the minimum dynamic performance of the mobile equipment to install has to be defined; the correct stiffness and stroke of the bearing assembly spring has to be calculated accurately. These are just a few examples of the questions that have to addressed and resolved when designing a complete crawler system. And finding the right answer and, most important, a reliable and optimized engineering solution, isn‘t always easy. Berco has been on the undercarriage components and machine tools market since 1920. Thanks to its expertise in the undercarriage field, developed over many years of activity, Berco can offer a vast range of complete solutions for crawler system OEMs in widely differing industrial areas (e.g. construction, mining, forestry, agriculture, road maintenance, drilling, etc...) and is capable of maximizing performance and optimizing costs and servicing. Berco has an extensive knowledge of how to produce undercarriage components and is familiar with the way the parts actually perform in the field when the machine is working. As a consequence Berco has decided to apply its know-how to complete track systems that are treated as multibodies. Structural simulation is very useful for previewing machine performance in the field. Using test equipment specially designed for undercarriage components, performance results can be obtained for single components (e.g. a track roller test rig that relates machine load, application, speed, oil and lubrication, geometric properties and thermal status). Subsequently, complete multibody simulation and prototyping make it possible to test the system as a whole after the optimization of all the individual parts. All the steps in the development, from the initial concept to the realization, are planned together with the OEM customer to be sure that the undercarriage system will be able to cope with all the technical and operational demands it will be subject to. All this knowledge, together with the most advanced production facilities and ISO9001:2000 quality standards, make it possible to have a product that everybody can rely on. Berco not only develops complete undercarriage systems capable of satisfying all customer needs but also provides support throughout the entire life of the product (from the first idea right through to field assistance) in order to create a mobile equipment unit really tailored to customer requirements. Berco - the competent partner you can rely on. We offer a wide range of applications and sizes. On the following pages you will see just a few examples of our products. Custom-oriented design is possible. Our complete undercarriage offer includes frames, track rollers, carrier rollers, track chains, final drive with sprockets, front idlers with track adjusters and shock absorbers. Frames are available both as sideframe only and/or together with carbody. Sideframes can be oscillating or fixed. 4 BTS COMPLETE TRACK SYSTEMS GENERIC UNDERCARRIAGE FRAMES • • • • • • REF BEX125/1840/7 BEX125/1905/7 BEX140/2100/6 BEX140/2404/7 BEX140/2544/8 BEX140/2553/9 BEX140/2699/9 BEX140/2721/9 BEX160/2584/8 BEX160/2646/9 BEX160/2820/8 BEX160/2820/9 BEX160/3000/8 BEX160/3300/9 BEX160/3300/9 BEX171,45/2935/7 BEX171,45/3280/8 BEX171,45/3280/8 BEX171,45/3800/9 BEX190/3166/7 BEX190/3258/8 BEX190/3707/9 BEX190/3707/9 BEX203,2/3790/10 BEX203,2/4284/10 BEX215,9/4350/10 BEX215,9/4993/11 BEX216/3608/7 BEX216/4374/11 BEX228,6/4014/7 BEX228,6/4350/8 BEX228,6/4442,5/9 BEX228,6/5490/11 BEX260,35/6375/12 UNDERCARRIAGE W O H (mm) (mm) (mm) 1840 1905 2100 2404 2544 2553 2699 2721 2584 2646 2820 2820 3000 3300 3300 2935 3280 3280 3800 3166 3258 3707 3707 3790 4284 4350 4993 3608 4374 4014 4350 4442,5 5490 6375 2358 2424 2850 2992 3132 3167 3311 3373 3356,5 3267 3545 3558 3729 4024 4024 3732 4077 4077 4597 3959 4199 4517 4517 4651 5229 5350 6001 4590 5365 4757 5093 5532 6600 7618 599 596 777 620 694 751,5 695 715 906 776 861 865 754 753 753 887 887 887 887 894 1051 938,5 938,5 1107 1032 1190 1282 1207 1059 886 886 1310 1387 1535 Standard layout dimensions are presented. Custom-tailored design on request. Sideframe or carbody supply. Wide choice of gear-boxes and hydraulic motors is available. Optional swing bearing plate and swivel joints are available. Various track shoe widths are available. GEAR BOX MT (Nm) TRACK CHAIN P (mm) TRACK ROLLER QTY (n°) CARRIER ROLLER QTY (n°) SPROCKET Z (n°) 8000 8000 20500 15000 15000 18000 15000 26000 21560 30000 24000 29866 26000 30000 26000 30000 30000 36000 40000 30087 60000 60000 60000 60000 70000 120000 120000 80000 80000 71687 71687 81170 130000 260000 125 125 140 140 140 140 140 140 160 160 160 160 160 160 160 171,45 171,45 171,45 171,45 190 190 190 190 203,2 203,2 215,9 215,9 216 216 228,6 228,6 228,6 228,6 260,35 7 7 6 7 8 9 9 9 8 9 8 9 8 9 9 7 8 8 9 7 8 9 9 10 10 10 11 7 11 7 8 9 11 12 1 1 1 0 1 2 1 2 1 2 1 1 0 0 0 2 2 2 2 2 2 3 2 2 2 2 3 2 2 2 2 3 3 4 21 21 27 21 21 21 21 23 27 19 23 23 23 23 23 23 23 23 23 21 23 21 21 21 23 23 23 23 23 21 21 23 23 23 BERCO, THE COMPETENT LEADER YOU CAN RELY ON DRILLING RIG FRAMES • Standard layout dimensions are presented. • Custom-tailored design on request. • Wide choice of gear-boxes and hydraulic motors is available. • Various track shoe widths are available. REF BDR140/2100/6 BDR125/1840/7 BDR140/2560/8 BDR160/2584/8 BDR160/2820/8 BDR140/2544/8 BDR140/2553/9 BDR160/2820/9 BDR140/2699/9 BDR160/2646/9 BDR203,2/3790/10 BDR216/3608/7 BDR215,9/4993/11 BDR260,35/6375/12 UNDERCARRIAGE GEAR BOX W O H MT (mm) (mm) (mm) (Nm) 2100 1840 2560 2584 2820 2544 2553 2820 2699 2646 3790 3608 4993 6375 2850 2358 3324 3356,5 3545 3132 3167 3558 3311 3267 4651 4590 6001 7618 777 599 847 906 861 694 751,5 865 695 776 1107 1207 1282 1535 20500 10000 21560 21560 24000 15000 18000 29866 15000 30000 60000 80000 120000 260000 TRACK CHAIN P (mm) 140 125 140 160 160 140 140 160 140 160 203,2 216 215,9 260,35 TRACK ROLLER CARRIER ROLLER SPROCKET QTY QTY Z (n°) (n°) (n°) 6 7 8 8 8 8 9 9 9 9 10 7 11 12 1 1 1 1 1 1 2 1 1 2 2 2 3 4 27 21 27 27 23 21 21 23 21 19 21 23 23 23 4 BTS COMPLETE TRACK SYSTEMS MOBILE CRUSHING PLANT FRAMES • Standard layout dimensions are shown. • Custom-tailored design on request. • Wide choice of gear-boxes and hydraulic motors is available. • Various track shoe widths are available. GEAR BOX TRACK CHAIN TRACK ROLLER CARRIER ROLLER W UNDERCARRIAGE O H MT P QTY QTY Z (mm) (mm) (mm) (Nm) (mm) (n°) (n°) (n°) BCR125/1840/7 1840 2358 599 8000 125 7 1 21 BCR125/1905/7 1905 2424 596 8000 125 7 1 21 BCR140/2100/6 2100 2850 777 20500 140 6 1 27 BCR140/2404/7 2404 2992 620 15000 140 7 0 21 BCR140/2544/8 2544 3132 694 15000 140 8 1 21 BCR140/2553/9 2553 3167 751,5 18000 140 9 2 21 BCR140/2699/9 2699 3311 695 15000 140 9 1 21 BCR140/2721/9 2721 3373 715 26000 140 9 2 23 BCR160/2584/8 2584 3356,5 906 21560 160 8 1 27 BCR160/2646/9 2646 3267 776 30000 160 9 2 19 BCR160/2820/8 2820 3545 861 24000 160 8 1 23 BCR160/2820/9 2820 3558 865 29866 160 9 1 23 BCR160/3000/8 3000 3729 754 26000 160 8 0 23 BCR160/3300/9 3300 4024 753 30000 160 9 0 23 BCR160/3300/9 3300 4024 753 26000 160 9 0 23 BCR171,45/2935/7 2935 3732 887 30000 171,45 7 2 23 BCR171,45/3280/8 3280 4077 887 30000 171,45 8 2 23 BCR171,45/3280/8 3280 4077 887 36000 171,45 8 2 23 BCR171,45/3800/9 3800 4597 887 40000 171,45 9 2 23 BCR190/3166/7 3166 3959 894 30087 190 7 2 21 BCR190/3258/8 3258 4199 1051 60000 190 8 2 23 BCR190/3707/9 3707 4517 938,5 60000 190 9 3 21 BCR190/3707/9 3707 4517 938,5 60000 190 9 2 21 BCR203,2/3790/10 3790 4651 1107 60000 203,2 10 2 21 BCR203,2/4284/10 4284 5229 1032 70000 203,2 10 2 23 BCR215,9/4350/10 4350 5350 1190 120000 215,9 10 2 23 BCR215,9/4993/11 4993 6001 1282 120000 215,9 11 3 23 BCR216/3608/7 3608 4590 1207 80000 216 7 2 23 BCR216/4374/11 4374 5365 1059 80000 216 11 2 23 BCR228,6/4014/7 4014 4757 886 71687 228,6 7 2 21 BCR228,6/4350/8 4350 5093 886 71687 228,6 8 2 21 BCR228,6/4442,5/9 4442,5 5532 1310 81170 228,6 9 3 23 BCR228,6/5490/11 5490 6600 1387 130000 228,6 11 3 23 BCR260,35/6375/12 6375 7618 1535 260000 260,35 12 4 23 REF SPROCKET BERCO, THE COMPETENT LEADER YOU CAN RELY ON ASPHALT PAVERS • • • • Standard layout dimensions are presented. Custom-tailored design on request. Wide choice of gear-boxes and hydraulic motors is available. Track chain with rubberized shoes. REF BAS155,57/3060/10 BAS155,57/3060/11 BAS155,57/2830/8 BAS155,57/3320/11 UNDERCARRIAGE GEAR BOX W O H MT (mm) (mm) (mm) (Nm) 3060 3060 2830 3320 3711 3711 3481 4060 747 748 746 857 36000 36000 36000 80000 TRACK CHAIN P (mm) 155,57 155,57 155,57 155,57 TRACK ROLLER CARRIER ROLLER SPROCKET QTY QTY Z (n°) (n°) (n°) 10 11 8 11 0 0 0 0 23 23 23 27 4 BTS COMPLETE TRACK SYSTEMS MILLING MACHINES (ROAD AND MINING) • Standard layout dimensions are presented. • Custom-tailored design on request. • Wide choice of gear-boxes and hydraulic motors is available. • Different choice of track chain: - Standard steel chain; - Special track chain with polyurethane shoes; REF BML140/804/3 BML155,57/1209/4 BML171,45/1326/4 BML171,45/1325/4 BML175,5/1450/4 BML175,5/1450/4 BML215,9/1981/5 BML260,35/2665/5 UNDERCARRIAGE GEAR BOX W O H MT (mm) (mm) (mm) (Nm) 804 1209 1326 1325 1450 1450 1981 2665 1348 1840 2021 2009 2212 2198 2965 3912 573 662 743 721,5 793 784 1014 1273 10000 30000 18000 18000 36000 36000 60000 143454 TRACK CHAIN P (mm) 140 155,57 171,45 171,45 175,5 175,5 215,9 260,35 TRACK ROLLER CARRIER ROLLER SPROCKET QTY QTY Z (n°) (n°) (n°) 3 4 4 4 4 4 5 5 0 0 0 0 0 0 0 0 17 19 17 17 19 19 21 23 BERCO, THE COMPETENT LEADER YOU CAN RELY ON MINI EXCAVATORS • Mini excavators, utility-use or special application machines. • Standard layout dimensions are presented. • Metal track chains with 2-grousers, 3-grousers, rubber pads or rubber belt options. • Custom-tailored design on request. • Sideframe only or the whole carbody supply. • Wide choice of gear-boxes and hydraulic motors is available. • Optional swing bearing plate and swivel joints are available. REF BME90/1100/4 BME101,6/1500/5 BME135/1925/5 UNDERCARRIAGE GEAR BOX W O H MT (mm) (mm) (mm) (Nm) 1100 1500 1925 1460 1973 2445 366 484 550 1200 1900 3500 TRACK CHAIN P (mm) 90 101,6 135 TRACK ROLLER CARRIER ROLLER SPROCKET QTY QTY Z (n°) (n°) (n°) 4 5 5 1 1 1 19 19 19 MAKING A SUPERIOR PRODUCT ADDING VALUE TO YOUR BUSINESS State-of-the-art 3D modeling, Finite Element Analysis (FEM) and Rapid Prototyping enables to design, optimize and evaluate a component before it is built. Artificial Intelligence techniques are currently being developed to automatically inspect 100% of components. Reliability Test on components are carried out to determine life and performance in a variety of field applications. Berco Metallurgy Laboratory employs advanced machines such as an electron microscope with microanalysis, a spectrophotometer, tribometers for wear tests, MTS presses for static and fatigue tests (also at extreme temperatures -70°C ÷ 250°C) on materials and components. Huge efforts are also devoted to the development of New Materials and improvement of the Heat Treating Processes, to guarantee longer product life and superior products. Photo-elasticity and Strain Gauge techniques are commonly used for stress and fatigue analysis on individual and assembled components. Berco adds value not only to the products but also to Your Business. STATE OF THE ART PRODUCTION With a capacity of over 250,000 tons of finished product, Berco manufactures more than 180,000 track chains, 6,000,000 track shoes, 1,300,000 rollers and 380,000 idlers and sprockets per year. Track links are forged, quenched, tempered, machined and induction hardened on the rail surface. Bushings are turned and drilled in double spindle lathes, case hardened, ground and superfinished (lapped) for longer seal life. Track shoes are either hot rolled or forged for optimum internal grain flow and stronger core resistance, through hardened and stress relieved for perfect geometry and excellent resistance to bending. Complete track chains are then assembled in a fully automatic transfer line (Berco Design) where all important parameters (torque, lubrication, seals positioning, etc.) are monitored. Rollers are forged in two halves, welded in automated welding stations, through hardened, machined and finally assembled with shafts, hubs, collars and seal groups. Sprockets are forged for optimum internal grain flow and stronger core resistance, machined and induction hardened on the entire tooth profile. Idlers are fabricated by automated welding of hot rolled rail rims (one piece) with heat treated forged hub and high resistance side plates. Painting completes the process while final inspection on the finished products guarantees the Total Quality of all components. AUTOMATED PROCESSES AUTOMATIC QUALITY The entire production process is fully automated and computer controlled via Computer Manufacturing Technology systems. This guarantees a highly reliable process and constant quality of the products. THE RIGHT PRODUCT AT THE RIGHT TIME A vast variety of raw materials and flexible manufacturing give the competitive advantage of short lead times while matching your specific need. That’s what we also call Customer Satisfaction. HEAT TREATED TO TREAT YOU EVEN BETTER Quality materials and state-of-the-art manufacturing are not enough to guarantee the quality of the finished products. That’s why the heat treating processes are carried out making sure that all process parameters (temperature gradients, time, quenching temperature, etc.) are constantly monitored online. Hardening and tempering upgrade mechanical properties for superior wear resistance, stress relieving guarantees perfect geometry and excellent resistance for longer product life. 13 INPUT DATA SHEET In order to design a correct crawler system, we require the following data from you: PRODUCT REQUESTED: Machine type / application: _________________________________________________________________________________________________________________________ Sideframe: YES NO Complete undercarriage frame: YES NO GENERAL INPUT DATA: Total machine weight (static / dynamic): ___________________________________Kg Weight distribution (CG position): ___________________________________ Power available for translation per side: ___________________________________kW Undercarriage size now used: ___________________________________________________________________ Soil conditions: _________________________________________________________________________________________ REQUESTED PERFORMANCE: Total pull force: F _____________________________________ kN Max vehicle translational speed: V _____________________________________ Km/h Gradeability: G _____________________________________ % Max bending moment: M _____________________________________ kN-m Ground pressure: GP _____________________________________ Kgf/cm2 Maneuvrability special requests, min turning radius: ________________________________ m REQUESTED DIMENSIONS: Carriage pitch: A _____________________________________ mm Total length: B _____________________________________ mm Track gauge: I _____________________________________ mm Track shoe width, mm: C _____________________________________ mm Total width: W _____________________________________ mm Total carriage height: H ________________________________________________ mm Total sideframe height: h _______________________________________________ mm Clear span from ground (headroom): cs ________________________________________________ mm __________________________________ - AVAILABLE POWER PLANT - HYDRAULIC PUMP: Number of pumps: Pump displacement: Dp __________________________ cc Pump speed: n __________________________ rpm Hydraulic system max pressure: ρs _____________________________________ bar Working pressure (max differential output): Δp _____________________________________ bar Flow rate per pump: Q l/min _____________________________________ REQUESTED FEATURES: Oscillating sideframes: YES NO Welded sideframes: YES NO Bolted sideframes: YES NO Track type METAL TRACK RUBBER BELT Track shoes 1 GROUSER 2 GROUSERS 3 GROUSERS CLIPPED MUD SLOT PU RUBBER Fixed / Variable displacement motors: Fixed Variable Are stabilizers / levelling jacks used during working cycle?: YES NO Planned annual demand _______________________________________________________________________________________________________________________________ Expected implementation time _________________________________________________________________________________________________________________________ Special application conditions __________________________________________________________________________________________________________________________ ISO 9001 Cert. n. 0029/6 ISO 14001 Cert. n. 0009A/3 All manufacturers’s names, numbers, symbols and descriptions are used for reference purposes only. All parts listed are of Berco original production.The specifications and processes described in this brochure are subject to change without notice 01111.WR433GB00C Published by Berco Communications Dept. BERCO S.p.A. Via 1° Maggio, 237 44034 Copparo (FE) Italy Tel. +39 0532 864 111 Fax +39 0532 864 259 info@berco.com www.berco.com Your Berco Dealer: