Welding Bull Wheel

Our cooperation with Tesmec demonstrates our advanced manufacturing capabilities in the field of power transmission and stringing equipment, particularly in the production of large and high-precision mechanical components for digital stringing machines.

Tesmec is an international industrial group specializing in technologies and solutions for the construction, maintenance, and management of strategic infrastructure. Its Energy-Stringing business provides digital stringing systems and equipment for the construction and maintenance of overhead and underground power lines. In this cooperation, Hehua Machinery Technology (Kunshan) Co., Ltd. provided precision manufacturing and fabrication support for a critical component used in Tesmec's digital stringing equipment.

The specific product is a Welding Bull Wheel for Digital Puller Tensioner. The bull wheel is a key mechanical component used in digital stringing machines for cable and conductor installation. During stringing operations, the equipment must provide controlled pulling and tensioning forces while maintaining stable and reliable mechanical performance. Therefore, the bull wheel requires high structural strength, dimensional accuracy, and reliable machining quality.

This project includes two different bull wheel components with sizes of Ø1405 × 1210 mm and Ø1463 × 365 mm, with corresponding weights of approximately 1930 kg and 580 kg. The large dimensions and heavy weight of these components place high demands on material preparation, welding, machining, dimensional control, and overall structural stability.

The bull wheels are manufactured from high-strength structural and mechanical steel materials, including S275JR, S355J2, and E355. These materials provide the required combination of mechanical strength, toughness, and machinability for large industrial components subjected to demanding mechanical loads during operation.

The manufacturing process combines lathing, welding, and machining. Welding is used to fabricate and integrate the major structural sections of the bull wheel, while subsequent machining operations are carried out to achieve the required dimensional accuracy and geometric precision. Due to the large size and weight of the components, strict process control is required throughout fabrication and machining to maintain structural integrity and dimensional consistency.

After welding and fabrication, the components undergo a controlled heat stress relieving treatment at 400°C. This process helps reduce residual stresses generated during welding and fabrication, improving dimensional stability during subsequent machining and supporting the overall reliability of the finished bull wheel.

The surface preparation process includes sandblasting to ISO 8501-1 Sa 2½, followed by the application of a primer coating. The surface treatment provides a properly prepared and protected surface for the finished component, helping improve corrosion protection and coating adhesion for the demanding working environment of power line stringing equipment.

Manufacturing large bull wheels requires close coordination between welding, stress relieving, machining, and surface treatment. Throughout the project, Hehua Machinery Technology (Kunshan) Co., Ltd. focuses on structural accuracy, machining precision, welding quality, and dimensional consistency to ensure that the finished components meet the customer's technical requirements and can be reliably integrated into digital stringing machines.

The successful cooperation with Tesmec reflects our ability to manufacture large-scale and heavy-duty welded components for international industrial equipment manufacturers. By integrating welding, heat stress relieving, lathing, precision machining, sandblasting, and primer application, we provide complete manufacturing solutions for critical mechanical components used in power transmission infrastructure.

This project further demonstrates our experience in supporting the global power transmission and stringing equipment industry with customized heavy fabrication and precision-machined components, contributing to the reliable construction and maintenance of overhead power line infrastructure.