WR410GB00C.

qxp 15-04-2010 10:46 Pagina 1

Rollers
The Widest Choice

A Company of
ThyssenKrupp
BERCO S.p.A.
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Berco
Moving Your Business Ahead

Leadership in Getting the Most from Berco Process Control

Undercarriage your Undercarriage Berco builds value &
For about 90 years Berco’s Since 1920 Berco has durability into every
leadership and research has continued to innovate and undercarriage component.
resulted in the greatest improve undercarriage Berco controls processes
undercarriage value. performance. High-quality critical to durability and
Quality is the critical link materials and careful value, such as: design, raw
that assures the maximum manufacturing processes material, heat treating,
productivity of your ensure that Berco manufacturing and because
machine. No one has undercarriage components Berco has control over
invested more than Berco are reliable, durable and these processes,
to assure dependable wear at a predictable rate. our undercarriages wear at
High Quality Undercarriage. Longer life and controllable a predictable rate and can
Berco starts with the wear mean that you be managed as a system.
highest quality steel, then get maximum
controls hardened depth undercarriage performance
along with other at the lowest operating
performance features. cost. At Berco we call it
As a result Berco’s Best Undercarriage Value”
“B
undercarriage is second to
none for extended wear life
and value.
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Rollers
The Widest Choice

Berco Rollers
Designed and manufactured for longer life and lowest cost.
Berco’s through hardening or differential quenching
processes increase wear life, provide superior structural
support and resistance to deformation. Berco’s exclusive
seal groups help ensure lifetime lubrication for extended life
and to reduce your costs. Berco offers the widest variety of
rollers to meet your work environment requirements.

Your Best Undercarriage Value

• Hot forged in two halves to obtain best internal grain flow
• Specific low alloyed boron steel for high hardenability
• Differential quenching or through hardening heat
treatment of the roller shell guarantees a rail surface with
a superior wear resistance (HRC> 50); optimum core and
internal shell surface hardness for extreme resistance to
shock and fatigue stresses caused by the most severe
applications
• Induction hardening and super finishing of the shafts
• Large bearing and bushing area for high resistance to
radial loads
• Sizeable oil capacity and perfect sealing
• Maintenance free, for longer life and perfect operation
under any working condition
• Precise design and carefully manufactured for perfect
alignment, perfect fit of bushings and final assembly of
the components
• Easy re-shelling

The Widest Choice

• Single Flange, Double Flange and Inner Flange rollers
• Ultra low temperature (-50°C) version available
• More than 1,500 different rollers, to match any chain or
application
• For track-type machines ranging from 1 to 400 ton
• The choice of the leading OEMs

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.
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Rollers
Quality Components

Hub Shaft
Made of low alloyed forged
Made of cast iron, accurately
steel, Berco shafts are
machined guarantee correct fit
accurately machined using a
and high resistance to radial
fully automated process.
loads.
Surfaces in contact with
bushings are induction
hardened to guarantee
Bimetallic Bushing adequate hardness (HRC > 55)
The external steel shell prevents and superfinished to guarantee
deformations and guarantees long lasting bushings life.
perfect fit to the seats. The high
quality inner brass layer offers Heavy Duty Seal Group
excellent antifriction properties are fundamental for roller life,
for longer life are obtained from high alloyed
cast iron (or from forging of
special alloyed steel) with
Collar hardness HRC>63 and accurate
superfinishing (lapping) of the
Made of high resistance contact surfaces. High quality
nodular cast iron, Berco collars rubber ring and exact design of
offer maximum strength and the seats guarantee perfect
resistance to radial loads. sealing in all working
Accurate machining and high conditions.
quality control guarantee
perfect fit with the other parts
of the roller.
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Adding Value to Our Products

Adding value to Your Business

FEM analysis of deformation during

hot forging using “Marc”
superplasticity software.
This tecnology gives the possibility to
identify in advance critical factors
(material flow, material foldings,
cracks and/or cavities, etc.) and to
optimize the whole forging process
(die and bilet geometry, mechanical
properties, etc.) in order to maximize
the product quality.

Making a Superior Product

It all begins in the design stage, Reliability Test on components
Berco Research & Development (ex. rollers) are carried out to
engineers employ state of the determine life and performance
art computer design. The use in a variety of field applications.
of 3D modeling and finite
element analysis (FEM) allow us Artificial Intelligence and Vision
to design and evaluate a techniques are currently being
component before it is built. developed to automatically
inspect 100% of components.
Our Rapid Prototyping enables This reduces defects (ex. after
Berco’s engineers to optimize a forging or heat treatment) Rapid prototyping
design before spending money attributable to manufacturing to
in tooling. almost zero.

Berco Metallurgy Laboratory Huge efforts are also devoted

employs advanced machines to the development of
such as an electron microscope New Materials and
with microanalysis, a improvement of the
spectrophotometer, tribometers Heat Treating Processes, to
for wear tests, MTS presses for guarantee longer product life
static and fatigue tests on and Superior Products.
Electron microscope with
materials and components. microanalysis
Having supplied leading OEMs
Photo-elasticity and strain for decades, Berco’s Engineers
gauge techniques are and product specialists can
commonly used for stress and help you design and
fatigue analysis on individual manufacture the right
and assembled components. undercarriage, using high tech
software, tools and expertise.
Stress analysis at extreme Berco can also help you reduce
temperatures (-70°C ÷ 250°C) development and engineering
are also carried out. time, tooling expenses and
facility costs. Berco Adds Value
not only to our products but
also to Your Business.

Stress analysis at extreme

temperatures
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State of the Art Production

State of the Art Components

With a capacity of over 40,000 ton of finished product the Berco Rollers
Department manufactures more than 1,000,000 rollers per year. From the
central raw material warehouse the steel bars are transferred to one of the
induction heating/hot shearing and hot forging stations where semi-shells
are obtained. The two halves are then welded in one of the automatic
welding centers. Heat treatment and mechanical machining complete the
manufacturing of these components. In the Berco Shaft Department, forged
shafts are loaded in the robot assisted manufacturing lines where they are
Through hardening furnace machined in lathes, deep drilling machines and machining centers.
Induction heat treatment and final grinding complete the fully automated
operation. Online control at each stage of the process, guarantees the total
quality of each component. Collars, hubs and seal groups are also
manufactured in house and are assembled together with shells and shafts,
to obtain the finished rollers. Painting completes the process while final
inspections of the finished products guarantees the Total Quality of all
components.
Heat Treated to Automated Processes
Automated welding station Treat You Even Better Automatic Quality
Quality materials and state-of-art The entire production process is
manufacturing are not enough to fully automated and computer
guarantee the quality of the controlled via Computer
finished products. Manufacturing Technology
That’s why the heat treating of system. This guarantees highly
roller shells is carried out in a reliable processes and constant
specific furnace where all quality of the products
process parameters
(temperature gradients, time, The Right Product at
quenching temperature, etc.) are The Right Time
Shaft manufacturing line
constantly monitored online. A vast variety of raw materials
Shaft induction hardening Differential quenching and/or and flexible manufacturing give
through hardening together with the competitive advantage of
tempering guarantee excellent short lead times while matching
mechanical properties and your specific need.
perfect geometry for longer That’s what we also call
product life. Customer Satisfaction.
Shafts are induction hardened
and surface finished to guarantee
excellent mechanical properties
and longer bushings life.
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We Care

Leadership in Customer Service

Environmental
Development We have a large dealer network
covering 70 countries in the
Not only do we care about our world. They have been in
customers supplying quality business for decades, they
products manufactured under know the business and they
ISO 9001 certified processes, know it from their customers’
but also we care about the point of view. They understand
Environment. customers’ needs and they
know that their success is tied to
Since Jan 2000 Berco is their customers’ successes.
ISO 14001 certified and has
adopted Environmental We support our dealers with our
Procedures throughout the entire professional sales force. We
manufacturing process. We have train them, we provide them
an Environmental Strategy and with the right marketing tools
we continuously check on the and advanced technological
progress made toward the set systems. We have developed a
Objectives. computer based integrated
system BOPIS (Berco Online
Getting More out of Less. Product Information System)
Reduction of energy consumption, enabling a dealer technician to
improved use of materials and use a laptop computer from the
minimization of waste, allows for a field to consult our database
lower impact on the environment. and easily find the right answer.
We have given preference to
environmentally friendly We back you, wherever you
transportation like trains and are. We work with our dealers to
boats and we have begun establish a parts and service
redesigning our packaging in presence near you, in order to
order to use recyclable materials. always have the right product at
We have changed our painting the right time in the right place.
processes and now use It is customer satisfaction that
environmentally friendly water- has built our Berco Track
based paint, with a reduction in Record.
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.
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01003.WR410GB00C Published by Berco Communication Dept.

ISO 9001 Cert. n. 0029/5

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

BERCO S.p.A. Your Berco dealer:

Via 1° Maggio, 237
44034 Copparo (Ferrara) Italy
Phone +39 0532 864 111
Fax +39 0532 864 259
www.berco.com
info@berco.com