Customer: Novocherkassk Electric Locomotive Plant
Implementation period: 2012-2013 р.
Project Overview
NPF Techvagonmash successfully completed a large-scale modernization project for the Novocherkassk Electric Locomotive Plant, one of the leading manufacturers of electric locomotives in Eastern Europe.
The project included the design, manufacturing, delivery, installation, and commissioning of specialized welding and assembly equipment intended for the production of locomotive body frame side structures. The supplied systems enabled a significant increase in production efficiency, welding quality, and manufacturing accuracy.
Supplied Equipment
Assembly and Welding Line for Locomotive Frame Side Structures
The core of the project was a fully integrated assembly and welding line designed for manufacturing locomotive frame side structures of various electric locomotive models.
The production line is capable of processing structures up to 21.4 meters long and weighing up to 4.5 tons, with an annual capacity of up to 1,200 side frames in a two-shift operation mode.
Scope of Supply
The supplied equipment included:
- Industrial cooling system.
- Strip assembly and automatic welding station;
- Channel installation and tack welding station;
- Transportation system for workpiece movement;
- Automatic longitudinal seam welding portal;
- Automatic channel tack welding portal;
- Transverse seam welding portal;
- Guide channel installation system;
- Operator control stations;
- Pneumatic control cabinets;
Advanced Welding Technologies
The production complex incorporates modern automation technologies that ensure:
- Accurate positioning and clamping of components;
- Automated longitudinal and transverse welding;
- Consistent weld quality;
- Reduced manual operations;
- Improved productivity;
- Increased repeatability of manufacturing processes;
- Enhanced operational safety.
The welding systems are equipped with advanced Fronius welding power sources, ensuring stable arc performance and high-quality welds for critical locomotive structures.
Universal Welding Positioner
As part of the modernization project, Techvagonmash also supplied a heavy-duty universal welding positioner.
The positioner is designed for rotating and positioning locomotive body frames during welding operations, providing optimal access to weld joints and improving both productivity and weld quality.
Project Results
Implementation of Techvagonmash equipment enabled NEVZ to:
- Automate critical assembly and welding operations;
- Increase production capacity;
- Improve welding quality and consistency;
- Reduce manufacturing cycle times;
- Enhance workplace safety;
- Increase flexibility in the production of various locomotive models.