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.