Car manufacturing plants and rolling stock manufacturers. How cars are made for Russian Railways Modifications "Ezh" and "Em"

The Soviet Union, within the boundaries of a single enterprise, in my opinion, did not even think about disintegrating. A checkpoint with turnstiles and grandmothers in blue vests, one-time passes and a memorial plaque on the wall.

Generations change. The interiors and appearance of the cars too. And the manufacturer remains the same, Mytishchi MetroVagonMash. While the USSR was alive, the carriages were sent to other republics. Today the flow of exports has almost dried up, but orders from the Moscow metro are arriving regularly.

Today we’ll take a walk around the plant and see how cars for the Russian capital’s metro are made from scratch.

*reposted*

1 There are not many factories in the world that produce cars for subways. There are several world leaders that supply formulations to customers from different countries. We have our own carriages.

2 Monument to a subway car. Very controversial. Some people think it’s beautiful, but oh well. There’s something else that’s more interesting to me: the windows in the entire plant management building were replaced with fancy double-glazed windows. Why didn’t they update the façade at the same time? These long-outdated Soviet façade tiles look much worse than wooden windows.

3 Inside there is perfect cleanliness, but the same despondency. Everything is old, Soviet, repainted a thousand times. Personally, I wouldn't feel comfortable coming here every day.

4 I saw exactly the same interiors at dozens of other factories in Russia, not connected with each other. Quality and professionalism need to be improved, there is no doubt about it. But was it really impossible to update the interiors and make repairs? All this was built almost half a century ago.

5 I hope that the factory workers are not susceptible to such sentiments, and they like everything.

6 The product turns out new and shiny.

7 Especially for TV journalists, they placed this perfectly dressed and made-up girl in the workshop, who was doing something using a laptop and this construction. No one could answer what the essence of this work was.

8 In general, the interiors are interiors, and the equipment the men have is not the oldest. And not domestic.

9 But the general view is like this, yes.

10 And a machine is a machine, so what will happen to it?

11 Car welding shop. Here, from sheets of iron, familiar shapes with windows and doors are born.

12 There is nothing inside yet.

14 Then they begin to attach painted parts to the bare skeleton: the muzzle, the sides. The steel frame remains inside, probably for safety.

15 Glass, doors, and all intra-car equipment are installed.

16 A journalist from some TV channel is showing you her legs.

17 Everyone is responsible for their own area of ​​work. This is done slowly, there is no conveyor belt: it takes more time to assemble one subway car than a car. A person comes to work and begins to string wires, install sensors and elements, and tighten nuts.

18 Each carriage has an incredible number of wires and systems. The passenger doesn't see any of this.

19 The final station is written on the head car. I wonder who is this useful and convenient for? It would be better if, when leaving the escalator, they wrote the end stations on the paths to the right and left, and not the mysterious “path 1-2”.

20 Connectors. This is only a tenth of the wires connected to each car. What is responsible for what - I have no idea :) But the mother-father system was borrowed from computer scientists, you can never make a mistake about what to plug into where.

21 Completely finished, assembled carriage.

22 After assembly, each car and train must be tested and then sent to a storage warehouse until it is time to transfer them to Moscow.

23 I was terribly thirsty, and I kept looking for a drinking fountain. What kind of Soviet factory is this without fountains? He was found.

24 And there is also a machine that dispenses soda! Well, that’s for sure, all Soviet factories are the same in structure.

25 Warehouse of finished cars. They are already numbered for the Moscow metro. You can roughly estimate how many there are today.

26 Train running-in line. There is no contact rail like in the subway. That’s why they run it in with a regular diesel locomotive.

27 Did you notice that this train is radically different in color from the blue-gray ones we are used to? At first I thought that mosmetro had finally figured out to paint the trains of each line in its own color, and that would be very cool! Almost . But no, this train is intended for export, for Azerbaijanis.

28 The eggplant color seems to refer us to the famous purple ones, but at the same time, after I published a picture of this train in Facebook, a real dispute broke out among Baku journalists, which resulted in a denial: the Baku metro did not purchase any cars from MetroVagonMasha. Someone is lying here...

29 But the main “trick” and the difference between these “Baku” cars and Moscow ones is free passage through the entire train. Did you notice the “accordions” in the last photo? I like this option much better, and it’s a shame that Moscow still hasn’t thought of purchasing these, since the plant has the ability to do this...at least they tried.

30 Gone are the days when two people drove metro trains. On almost all lines, the position of assistant driver has disappeared. They could also make automatic trains, but our metro is probably not ready for this yet. He is getting old, and there may be more and more emergency situations.

31 By the way, about the abnormal. If you are traveling on a train of the type shown in the photographs of this report, in any unclear situation, run to the beginning or end of the train. It’s not entirely clear how you can independently move from car to car, but additional emergency exits are provided in the head and tail, directly from the driver’s cab.

32 This is how the excursion turned out. It was interesting, although I expected more.

33 And on trains near Moscow, with the arrival of warm weather, the zatsepera bloomed again in magnificent colors. Last year, TsPPK, the company servicing electric trains, was going to organize raids on them, and also explain to conscious passengers that such “extreme bunnies” should be reported where they should be in order to eradicate the phenomenon as a class. But the catchers drive, even the employees don’t pay attention to them. Despite the fact that these assholes create a danger for other passengers. It's good that there are no such things in the metro.

Reports about the world's subways.

I was a little shocked when I found out how many passengers the Moscow metro carries every year. It turned out that in 2013 alone, no less than 2.5 billion passengers were transported!!! I decided to see how the process of assembling cars takes place and went to the Metrovagonmash plant...

Every day, millions of passengers, having descended into the Moscow or St. Petersburg metro, board metro cars, which are made in the city of Mytishchi

Back in 1897, the Mytishchi Machine-Building Plant was founded. Its founders were the legendary Russian entrepreneur Savva Mamontov, nobleman Konstantin Artsybushev and a citizen of the North American United States, temporary Moscow 1st Guild merchant, engineer Alexander Bari, who in December 1895 submitted to the Russian Ministry of Finance the project of the “Moscow Joint Stock Company Carriage Building Plant”.

The first products were passenger and freight cars for the Northern Railway of Russia. In 1903, production of tram cars for Moscow began.

A hundred years later, Metrovagonmash makes cars for the metro of Moscow, St. Petersburg, Baku, Tbilisi, Kharkov, Budapest, Prague and other cities of Russia, near and far abroad

To visit the plant I was given an “armored” baseball cap.

Car production begins in the procurement workshop

In the workshop, work is underway to procure products to supply all departments of the plant, and also make finished parts for the production itself

Plasma and laser cutting are also carried out in this workshop.

Wheelsets

Rolling stock bogies

Bogie and body assembly workshop

By the way, currently the length of the capital’s subway lines is 325.4 km, the number of lines is 12, stations are 194, and the inventory of cars is 4,935.

Body assembly/welding in progress

Work is underway in the workshop on the production of body components (roof, frame, sidewalls)

Mechanical processing is carried out

Be afraid of marriage-)

Workshop machine

After welding, the car enters the assembly shop

Painting, body assembly and adjustment of finished trains are carried out here.

Doing interior decoration

Carry out installation of electrical equipment

Installation of train ventilation systems

Hanging doors

Insert windows

The result is the well-known Moscow cars of the 81-760/761 series

The 81-760/761 series cars supplied to the metro are equipped with a ventilation, air conditioning and heating system for the passenger compartment, and a video surveillance system, which makes it possible to transmit images to the situation center.

The new carriages are equipped with an air disinfection system for the first time. The salons are equipped with electronic route boards and LCD screens.

The doors are equipped with light and sound alarms for door closing.

The design of the cars uses a modern asynchronous traction drive, a microprocessor control system, and a new suspension design that ensures smooth and quiet running of the train. The car bodies are made of stainless steel.

By the way, according to Sobyanin, the reliability of the Moscow metro today is the highest in the world. In the Paris and New York metro, which carry comparable numbers of passengers, the accident rate is three times higher, and in London - more than three times.

See the original material at

Car manufacturing plants are transport engineering enterprises that produce passenger and freight cars for the needs of railways.

In accordance with the technical characteristics, cars produced at car-building enterprises are classified:

• by the number of axles (four-, six-, eight-axle, multi-axle);
• according to the technology used in the manufacture of the body and the type of material (all-metal, with a body made of light alloys, with metal or wood cladding);
• by the structure of the chassis (non-trolley or trolley);
• by load capacity;
• by load per 1 linear meter of railway track;
• by dimensions;
• by wagon tare weight;
• by axial load.

Car manufacturing plants are replenishing the Russian carriage fleet with four-axle all-metal cars (compartment, reserved seat, interregional carriages, luxury cars), restaurant cars, postal, baggage, mail and luggage cars, and special-purpose cars.

Freight cars produced by Russian carriage-building enterprises are represented by covered cars, flat cars, gondola cars, tanks, isothermal cars, hopper cars, and special-purpose cars (for example, for transporting radioactive waste).

In addition, carriage factories produce self-propelled motor electrified electric train cars, subway cars and diesel trains, tram cars, as well as bogies for passenger cars and wheel sets.

Car manufacturing enterprises have main and auxiliary production. The main workshops include:

• car assembly;
• casting;
• cold-pressed;
• forging and pressing;
• trolley;
• frame-body;
• woodworking;
• headset

Auxiliary production processes are carried out in the following workshops:

• instrumental;
• boiler room;
• electric power;
• motor transport;
• painting;
• experimental;
• mechanical repair;
• experimental products.

In modern car building technology, various technological processes are widely used - mechanical, electrochemical, thermal, acoustic, electrical, chemical, etc. New cars are created using economical materials, light alloys, and welded structures. New progressive methods of forging and casting are being introduced into production. Standardization and unification of parts and assembly units ensures their interchangeability.

The history of Russian carriage building began in the middle of the 19th century. The first carriage structures for the Russian railway were created at the Sormovsky, Putilovsky, Kolomensky, Bryansk, St. Petersburg, Verkhne-Volzhsky, Mytishchi plants.

Every time I get to an interesting and large-scale production, I am ready to stay there for days, taking interesting shots, delving into the intricacies of production and technology. It's incredibly exciting. Today we will visit the largest enterprise in Russia and the CIS and see how train cars are made.

1. I arrived at the Tver Carriage Works around 10 am, and initially planned to finish in time for the presentation of the new electric train. But where is it? By two o'clock we had just filmed the workshops where components are produced... and after the presentation we finally got down to the most important thing - the assembly shops. My escorts clearly planned to leave work on time - at 17:00, but, sorry, it’s simply impossible to leave early. As a result, the shooting ended at half past seven, and even then there were still a lot of moments left that could be watched.

And then - another problem. During production I shot over 1,000 frames. Defects, repetitions and bad angles were thrown out immediately. By the way, this turned out to be 800-odd frames in the basket. And space was saved. Another hundred will be thrown out after a second pass. And then the painstaking work begins: how to choose from the remaining 300 those needed for the post. This is hell, friends, in fact. The fact is that a very complex and multifaceted production was filmed, and I want to show everything. Some shots are needed to understand technical processes, and some are simply beautiful.

So, after a short introduction - Tver Carriage Works. The largest enterprise in Russia and the CIS for the production of various types of passenger cars and components for them. The main supplier of cars for JSC Russian Railways.

The existing production areas and technological capacities allow us to simultaneously carry out work on the production of several models of passenger cars, as well as various types of freight cars and special-purpose cars.

The plant was founded in 1898 by the French-Belgian joint-stock company "Dil and Bacalan" under the name "Verkhnevolzhsky Plant of Railway Materials". In 1915, it was renamed the Tver Russian-Baltic Carriage Works, and after nationalization (in 1918) - the Tver Carriage Works.

02. From the first years of the 20th century, the era of passenger carriage construction began at the plant. An archival photograph shows a double-decker carriage created at TVZ in 1905:

03. The plant has a huge area in Tver, and in fact it is the only large operating enterprise in this city. On the territory you can see buildings of various eras and types. For example, in the photo you see the oldest building - a wooden frame of the water tower of the local boiler house. It has been standing since the 19th century:

04. But we start our tour from the woodworking workshop. Nowadays, very little wood is used in a modern carriage, but previously almost the entire carriage was made of wood. This machine makes parts of any configuration in a matter of minutes, the accuracy is the highest, which accordingly affects the accuracy and speed of assembly of finished cars.

05. A worker glues rubber seals onto compartment doors with superglue. It’s about half past 12 in the morning, and he’s already used up so many tubes of glue:

06. The machine simultaneously saws four metal profiles, which will later become part of the internal equipment of the car:

07. Now let’s go through and see how the metal parts of the future carriage are made. This is a sheet of metal after plasma cutting:

08. Stamping machines. Some small fittings and parts, when the quantity used is large, are not profitable to make using new technologies (expensive and less productive), so they use such a machine park. And next to it stands an old press from very shaggy years. But in absolutely working condition.

09. Parts are painted with powder paints on an automatic line.

10. Now it's time to make the frames for the undercarriages. The automatic robot welder comes into play. Hard-to-reach places are boiled manually:

11. Almost finished cart frame:

12. Production of wheelsets:

13. Attaching the wheel to the axle. There is a hot and cold nozzle method. Cold is used here. The inner diameter of the hole in the wheel is slightly smaller than the outer diameter of the axle. And the wheel is pressed onto the axle:

14. Finished wheelsets are sent for bogie assembly:

15. A finished bogie of a new passenger car design with disc brakes:

16. Now let’s go to the foundry. In this nondescript photo you see a literal technical revolution in the foundry business. If you need to cast a simple part without cavities inside, then it’s all simple. But what if the part is complex and there are cavities and channels inside? Internal cavities are formed using sand models. Previously, they were compacted by hand, but now sand models are made by machine. The result of her work is in the photo:

17. Issuing cast iron:

18. They manage to fill several flasks and go back to dispensing cast iron:

19. Now let's go look at the body assembly. First, the car frame is welded, then the undercar equipment is installed and communications are laid.

20. In parallel with the assembly of body frames, car sidewalls are manufactured on a special line:

21. The roof sheathing is first welded flat, then turned over and given a semicircular shape on a special stand:

22. Finally, all parts of the body (frame, sides, end walls and roof) are connected together into a finished product - the basis of the future car:

23. The carriage is almost ready. At least its frame:

24. The car after applying the thermal insulation coating and flooring.

25. Next comes essentially the usual assembly of a huge number of components and testing them. Assembly is carried out at positions - at each only certain actions are performed. Then the car moves to the next position. They come here already painted:

26. The car after installing almost all internal systems. Now it’s time to install partitions and mount what the passenger will ultimately see.

Over the past three years, double-decker cars have ceased to be exotic on Russian railways: the first double-decker train set off in 2013 on the Moscow-Adler route (on the eve of the Winter Olympic Games in Sochi). Today, double-decker cars continue to conquer the passenger transportation market - they also run on the routes Moscow - St. Petersburg, Moscow - Kazan, Moscow - Voronezh, Moscow - Samara and St. Petersburg - Adler.

Several models of double-decker cars are produced - compartment, SV, staff, restaurant cars; carriages with seats in two versions (with standard and improved interior).

The project to create this new type of rolling stock for Russia - from the idea to its full implementation - was implemented by the Tver Freight Car Building Plant. Our story is about how the production of double-decker cars is organized at the Tver Carriage Plant.

The beginning of the journey of the car to the passenger can be considered (rather conditionally, of course) the delivery of materials to the plant. Here, in the cold press shop, stainless steel arrives by rail in rolls like these. What happens at this stage of production can be explained at the everyday level by drawing an analogy with a sewing workshop; it is here that the parts of the future carriage are cut out of metal using special equipment.

The steel is first passed through slitting or cross cutting lines. Then rolls of the required width are supplied to the rolling line to produce parts of the required profiles. The sheets after the cross cutting line are sent to special laser cutting machines, where they are cut into parts.

Here, in the cold press shop, the molding of volumetric parts and the production of bent profiles take place. Precise bending of workpieces is carried out on CNC press brakes.

The use of laser technologies for cutting metal reduces the amount of waste by almost a third. All manipulations are performed by a computer-controlled machine; a person only “looks after” it - controls its actions.

Coordinate punching presses are distinguished by their high productivity and accuracy of cutting, punching and forming operations. Their use ensures that all cutting operations are performed automatically, with minimal operator intervention. This technology allows you to produce almost any part from a sheet of metal - any configuration and with any number of holes.

Modern high-performance machines produce up to ten or more blows per second. A punching machine operating in perforation mode produces a sound reminiscent of machine gun fire. The sheet of metal travels the entire path according to a given program.

While the workshops working with metal are making blanks for the body, the woodworking workshop is creating interior parts.

Internal partitions are made of plywood. Plywood boards up to 2 cm thick are easily and effortlessly cut using format cutting machines, and then complex parts of intra-car partitions are made at a processing center.

Then they are lined with plastic on the unique Italian “Barberan” line, manufactured to a special order of the Tver Carriage Plant. In this area, the specified temperature and humidity are always maintained, as required by the technology.

The molding of facing panels from polyvinyl chloride plastic is carried out here - on modern equipment from Geiss.

Aluminum profiles for fastening parts of the car interior and doors are machined using modern Eima machines.

And this is a “painting machine” - here the details of the interior on a specialized powder coating line acquire a durable and even color.

Meanwhile, in another workshop, components for the trolley are being prepared: axles, frames, wheelsets...

... and the bogies themselves, ready to “take over” the carriage.

Further stages of creating a car now relate to assembly production.

To organize the assembly and welding production of double-decker cars, the Tver Carriage Works rented premises from Tsentrosvarmash, since in order to assemble such large-sized parts as the sidewalls of double-decker cars, adequate space is needed. Original equipment manufactured by special order of TVZ OJSC is installed here.

Prepared parts and blanks are placed on a kind of “bed”. A frame, the so-called “skeleton” of the future sidewall, is installed. Fixation and preliminary welding also take place here. Next, this entire structure falls on the contact welding line.

Ultra-modern high-speed spot welding equipment from the German company Calvorde allows you to significantly speed up the process of assembling the body side. During a shift, the machine, under the supervision of an operator, applies several thousand dots. The entire process is completely computer controlled. After this, the finished side wall of the double-decker car body comes out of the line.

The next stage of assembly takes place in the frame and body shop. It is here that the car body is assembled from individual parts, as if from a construction set.

The frame of the car body with the undercar equipment already installed on it is installed on the technological trolley in the slipway. The side walls are installed first, then the end walls. They are combined at the joints with the side ones and secured by electric arc welding.

The next stage is the installation of the inter-car floor (in other words, the floor of the second floor). Then the roof is placed on this structure using two cranes and the body takes on the shape of a carriage.

The assembled body undergoes thermal and mechanical straightening and a leak test. And after that it is submitted for inspection by Quality Control Department.

Next, the car is sent for painting. This is a complex and strictly regulated process. First, the surface of the walls is cleaned of dust and degreased using steam jet equipment, primed, leveled, and sanded. Then the thermal insulation material is applied. Each type of coating is thoroughly dried. And only after this the coloring process begins. The whole process takes place in special chambers.

Between workshops and sections, the car “travels” contrary to the laws of the railways - sideways, using a special device - a transborder.