Production of rollers
IMPLEMENTATION OF LARP-2020 PROJECT (Automated Roller Production Line) in Alabuga EPZ (Tatarstan, Yelabuga)
JSC “SIA “Akonit” is an exclusive partner of the steel structures and conveyor rollers production plant in Alabuga EPZ (Tatarstan, Yelabuga). The plant is aimed at manufacturing 1 mln. rollers per year. The manufacturers count upon the product quality that will allow increasing the component service life in 2 times as compared with other products in the market.
The construction and completing of the plant started in August of 2019. In late October of 2020 the plant was officially brought into operation. The plant is equipped with modern high-tech equipment.
PURPOSE AND AIMS OF A PROJECT
The project implementation allows:
1. Create a high-quality competitive product on the world market;
2. Establish stable partnership relations and have confidence in suppliers — Russian manufacturers of raw materials and components.
3. Satisfy the customer’s needs for a high-quality product within well-specified time.
4. Create an absolutely new modern automated production at the Industry 4.0 basis which has no parallel in Russia.
Process engineering solutions used in production are developed by JSC “SIA “Akonit” and patented: including design of the bearing protective device (labyrinth seal).
Our Company focuses on a simplicity of roller design and improved characteristics of the product: radial run-out, axial clearance, moment of resistance to rotation. Quality control at all production stages:
- thorough selection of component suppliers;
- requirements to ovality in electric-welded pipes became tougher;
- in-process control of rough parts, finished parts: at the area of pipe cutting, forging, processing of axes, inspection of parts for compliance with GOST.
Installation and welding of bearing housings in the prepared tube. Equipped with four welding robots (PANASONIC).
Round bar preparation area
Automatic line of round bar dressing and calibration (China) is used for calibration operations to improve characteristics of the initial round rolling stock: curvature, ovality, surface roughness.
Bearing housing forging area
The cutting out of the disk and its subsequent forging up to forming the part “bearing housing” is performed by means of the pressing machine which uses the system of decoiling and feeding to the cutting out area, the system of automatic transfer of rough parts (China).
Roller axis processing area
Machining of axes is performed on the turning machining centers (China) with a central spindle and two turret cutting heads. The axle necks are machined in parallel from both sides that allows an ideal alignment of seats for bearings.
Pipe processing area
It is equipped with the pipe cutting and bevelling line completed with the automated stock holder (Italy).
Roller assembly area
Assembly of the pipe welded to bearing housings with other components of the roller: axis, bearing, labyrinth seals is carried out in the automated conveyor roller assembly line (Italy) with the subsequent automatic inspection of output parameters of the roller.
Roller painting and drying area
Automatic conveyor roller painting line: painting of rollers and their subsequent drying is performed in a special chamber. The chamber is equipped with loading robots and painting robots (FANUC).
Stacking of finished products on the europallets, strapping with a tyre tape and wrapping with a stretch film are carried out in the automated conveyor roller packaging line (Russia).
You may order the conveyor rollers just now, filling in the Data Sheet in the Rollers section https://www.npoakonit.com/catalog/roliki
Conveyor rollers: how to purchase at a profit?
The roller is a component for the conveyor which plays an important role in efficiency and uninterrupted operations of equipment. Therefore, when choosing a supplier in the first instance pay attention to the specified service life of the conveyor roller. Its average service life in the market is 1.5–2 years.
JSC “SIA “Akonit” offers rollers with the service life of 2 times higher! It achieves among other things due to the conveyor roller production control and monitoring system at every production stage.
Organization of conveyor roller production
At the new roller manufacturing plant in Tatarstan the modern equipment is installed and the multi-stage inspection system will be implemented. This system starts at the stage of receiving raw materials and components which are checked for compliance with GOST.
During the incoming inspection the special attention is paid to the conveyor roller bearings. They pass 100% inspection on the specialized vibroacoustic unit operated with working and increase speed. The in-process control is carried out at every area of the manufacturing process in the automatic mode. In addition, the laboratory tests of components will be performed. It allows to be sure of the product quality and ensure the longer operating life of rollers and conveyor in whole.
The price of conveyor rollers made at the new plant is higher that the market price. However, it is fully compensated due to reduction of equipment maintenance costs and losses which the company would have during maintenance outage hours. In the future in six years the costs for acquisition of rollers is also reduced as half as much of rollers are required.
The full-scale production of rollers will start at the plant in Tatarstan in the third quarter of 2020.
You can order the conveyor rollers even today to any extent. Call JSC “SIA “Akonit” to discuss individual conditions: +7 (8172) 20-90-87.