In modern metro car manufacturing, automation plays a key role in improving efficiency and quality. The robotic assembly and welding complex for metro car roofs is designed to optimize manufacturing processes, ensuring high precision and reliability. If you are looking for advanced technologies for welding and assembling metal structures, this complex is the ideal choice for your enterprise.

Purpose of the Complex

The robotic assembly and welding complex for metro car roofs is specifically developed for automated assembly and welding operations. It enables the production of roofs for two different metro car models thanks to its reconfigurable design. To adapt to various roof frame types, the complex is equipped with interchangeable jigs, providing flexibility and minimizing downtime in production. This solution is perfect for factories manufacturing components for public transportation, such as metro systems, where high-precision MIG/MAG welding is required.

Operating Principle

The complex operation begins with placing roof frame components onto the support surfaces of the assembly stand using shop overhead handling equipment. The parts are aligned against stops, after which workers perform tack welding of the positioned elements.

The gantry with robots then moves from the standby zone to the roof assembly stand and stops above the roof. Moving along the gantry, the robots weld the roof frame in the reachable section. The gantry advances step-by-step, allowing the robots to weld the frame section by section.

Before welding each seam, the robot uses a laser tracking system to verify the exact seam position based on reference points. This enables correction of the torch path in the welding program, ensuring flawless weld quality without defects.

After frame welding, side and top skin sheets are placed on the frame and secured with stand clamps. Workers tack weld the sheets to each other and to the frame. Roof skin welding is performed in transverse and longitudinal directions:

• The gantry moves to the assembly stand, and robots weld the skin to the frame arcs.
• Pneumatic clamps on the gantry press the skin against the frame arcs at weld locations, while the pressure roller ensures longitudinal fixation.
• The process concludes with MIG/MAG welding of longitudinal skin seams.

Upon completion of roof welding, the gantry with robots automatically returns to the standby zone. The finished roof is released from clamps and fixtures, removed from the stand, and transported to the position for finish welding on the reverse side.

This operating principle minimizes manual labor, accelerates metro car roof production, and enhances workplace safety.

Control System

The robotic complex is controlled from a panel using touch screens and dedicated buttons. The operator selects the operating program based on the metro car roof model, enabling quick system reconfiguration. Control systems are built on Siemens programmable logic controllers, ensuring reliability, user-friendliness, and seamless integration with other production lines.

If you are interested in implementing robotic complexes for welding and assembly in your metro car manufacturing, this system offers the optimal combination of MIG/MAG welding technologies, automation, and flexibility. Contact us for implementation consultation!

The developed complex is designed to automate technological operations for assembly and welding of large-size sidewall panels of metro railcar bodies, meeting high requirements for geometric accuracy, weld quality, and repeatability of product parameters. The implementation of robotic technologies has significantly increased the productivity of the production area and ensured stable quality of the manufactured products.

The complex includes:

• assembly and welding fixtures with positioning and clamping systems for sidewall elements;
• industrial welding robots with CNC control;
• automated positioning and equipment synchronization systems;
• process control system with the ability to adapt welding modes to specific products;
• systems for monitoring geometric parameters and weld quality.

The project was implemented on a turnkey basis — from development of design documentation and technological solutions to manufacturing, assembly, commissioning, and commissioning into industrial operation at the customer’s production site.

As a result of implementing the robotic complex, CJSC “Metrovagonmash” received a modern high-efficiency solution that ensures:

• improved accuracy of sidewall assembly;
• enhanced quality of welded joints;
• reduced influence of the human factor;
• increased productivity and stability of the production process.

The implementation of this project confirmed the competencies of Techvagonmash in the field of designing and manufacturing automated and robotic technological complexes for transport engineering enterprises.

Comprehensive Equipment Supply for Passenger Railcar Production

As part of a large-scale technical modernization program, Tver Carriage Works is implementing a project aimed at launching the production of a new generation of passenger railcars, including double-deck coaches.

Research and Production Company “Techvagonmash” acted as a key partner in the project, providing design, manufacturing, supply, and commissioning of specialized технологical equipment for upgrading production processes.

Scope of Supply and Implemented Solutions

Within the framework of the project, more than 30 units of equipment were delivered, including:

• universal fixtures for railcar frame assembly;
• automated systems for welding roof sections;
• positioners for welding bogie frames and outer panels;
• assembly and welding fixtures/positioners for side walls;
• lifting platforms for painting areas;
• customized technological solutions tailored to customer requirements.

Particular attention should be paid to the innovative solutions developed:

• a universal positioner for floor panel welding and undercar equipment installation;
• a universal assembly fixture/positioner for side wall assembly.

The equipment was designed based on the principle of versatility, allowing quick adaptation for manufacturing various types of passenger railcars, electric trains, and metro cars.

Technological Features

The implemented solutions provide:

• production flexibility through movable structural elements;
• high welding accuracy achieved by using mobile gantry systems;
• improved productivity and occupational safety;
• the ability to work with railcars of different lengths and configurations.

Welding operations are carried out using independent gantry systems moving along guides mounted along the railcar structure, equipped with modern control and positioning systems.

Project Results

In 2012, commissioning works for the equipment complex used in the production of double-deck passenger railcars were successfully completed.

The project implementation made it possible to:

• launch the production of a new generation of passenger railcars;
• enhance the technological level of the enterprise;
• create a foundation for further expansion of the product range;
• increase flexibility and efficiency of production processes.