The manufacturing workshop is mainly used for manufacturing and overhaul. It covers an area of 1,000,358.66m2. The capacity is 1500 cars/year.
The bogie static load test bench, produced by the Swiss company NENCKI, uses a steel main frame structure with stable double-sided columns and horizontal beams to ensure the accuracy of the test results. The gauge adopts sensors and an automatic measuring system to realize fully automatic adjustment.
The main wheelsets and brake discs of the CNC wheelset press-fit machine are press-fitted by German MAE company. It can realize the automatic press-fitting of brake discs, wheels and axles, back pressure oil injection and unloading, etc., with a high degree of automation, which can be used every 8 hours. 20 sets of wheel sets are press-fitted.
The wheel set dynamic balance is mainly used for the dynamic balance test of the wheel set after pressing, to detect the unbalance amount and phase point of the wheel set and automatically mill to remove weight.
The FMS flexible intelligent processing center production line adopts the FMS flexible intelligent processing system and the processing CNC plane center. The processing line is controlled through software and electrical control system. It has extremely high automation and intelligence. It can be widely used in the bogie production of urban rail cars and municipal vehicles.
The equipment is produced by the Italian DEA company, and is composed of a host (Machine), a software system (Software System), and a detection system (Probing System). It is easy to operate and has high measurement accuracy, strong environmental adaptability and can meet various measurements, and has high safety. For large-size parts measurement can achieve high efficiency, high precision and operational reliability.
The skeleton of the annealing furnace is welded by various section steels. The outer frame is made of channel steel as the main beam, the coaming plate is made of cold thin plate, the trolley is made of channel steel as the main beam, and the bottom plate and front and rear plates are medium plates. This equipment is mainly used for stress-relieving annealing and aging heat treatment processes for frame weldments.
The machine adopts the layout form of movable worktable, fixed beam, plane frame structure, and bolted connection between double columns and both sides of the bed. The worktable moves longitudinally along the guide rail of the bed (X axis), the saddle moves laterally along the beam guide rail (Y axis), and the headstock moves up and down along the saddle (Z axis). This equipment is mainly used to process the welding grooves of beams and side beam components.
Each welding robot system is installed upside down by a RTe 499 welding robot, and can move in a straight line along the track axis left and right, up and down, and a rotatable and swingable C-shaped frame is arranged under the longitudinal slide rail beam with 2-axis dual-position displacement machine. The robot can rely on the orbital axis to move in the space above the welding station to ensure that the welding seam is reachable.
Under the control of the central computer, the coordinated actions of industrial robots, orbital moving axis, welding power supply and welding gun cleaning mechanism are automatically controlled. The welding robot is equipped with sensors for finding the starting point of the weld and tracking the weld.
The company has several internationally renowned IGM automated welding equipment manufacturers. Cover all the key processes of the traction sleeper, side walls, underframe, side beams, roof and car body. Among them, the 6-axis dedicated welding robot can ensure the accessibility of welding in a narrower space, and it is equipped with a tactile sensor type gas nozzle and a laser welding seam tracking sensor to ensure the quality of the welding seam.
The double-station aluminum alloy plane machining center is produced by the internationally renowned Fooke company, with high machining accuracy, high degree of automation and remarkable production efficiency. It adopts modern 5-axis linkage plane structure to move the beam structure, and is equipped with a wireless workpiece measurement system to automatically adjust the cutting position to ensure the cutting quality and improve the automation efficiency.
The plane movable type is equipped with a plane automatic spot welding robot, which is used for welding the side beams of the underframe and the corrugated floor of the underframe. At the same time, it is equipped with 2 manual spot welding machines and 1 set of balancer, which can realize manual welding for the welding of the underframe composition.
The side wall composite spot welding system adopts a plane movable structure, and welding can be carried out at any position in the length direction of the X axis. It is used for the welding of the outer panel and the frame of the side wall composed of the side wall of the urban rail stainless steel car body, the welding of the end wall frame and the wall panel, and the welding of the side wall composite.
The side wall skeleton spot welding system is a plane cantilever type, equipped with automatic and manual welding equipment. It can realize common rail operation of 2 welding equipment. The equipment is equipped with a quick pliers changing mechanism, and each equipment can use any handle pliers.
The car body composition system is symmetrically arranged on the left and right sides of the upper part of the workstation. Each suspension system can hang a set of fully automatic C-shaped welding guns to complete the combined spot welding of the roof and side walls, and can realize manual and automatic switching. Two sets of lower roundabout welding equipment (welding trolley form) are used to complete the combined spot welding of the side wall and the underframe. Two sets of plane systems, each plane hangs a manual X-type welding tongs to complete the combined spot welding of the end wall and the roof, the end wall and the side wall.
The logistics center is equipped with intelligent storage modes such as intelligent station storage, intelligent warehouse, and intelligent micro container. Through the use of intelligent AGV (automatic guided transport vehicle) to connect with the logistics management system, the automatic distribution of materials is realized to meet the production needs.
The preparation workshop is mainly responsible for the blanking of the production plates. All equipment is connected to the MES system, which can realize the real-time collection and analysis of data such as start time, completion time, completed quantity, and quality status. The workshop is equipped with many advanced numerical control equipment, using advanced steel pretreatment line, laser cutting machine production line.
The stainless steel car body workshop is responsible for the welding, rain test, and inspection of stainless steel car body parts. The plant covers an area of 29,700 square meters and introduces many world-class high-end welding equipment, including corrugated board seam welding machine, side wall composite electric welding system, etc.
The aluminum alloy car body workshop is responsible for the assembly welding, processing and polishing, and inspection of the aluminum alloy car body. The workshop is equipped with multiple automatic welding equipment and machining equipment, which are supplied by internationally renowned suppliers such as IGM and FOOKE.
The bogie frame workshop is equipped with a world-class welding flexible production line, which can automatically assemble the side beams and automatically weld the frame. The control room can detect and adjust the welding conditions.
The bogie workshop is equipped with 4 automated production lines and introduced the Japanese FMS flexible processing system. It is the first flexible and intelligent processing platform in China, which can realize the flexible processing of small batches of multiple varieties. At the same time, it is equipped with an intelligent assembly line for bogies, and independently controls the operation of the production line through MES, which realizes the rhythmic assembly line production of bogies. It can be applied to the bogies of urban rail vehicles and municipal vehicles.
The paint shop is responsible for the surface treatment of newly-built rail vehicles. It has 39 stations, equipped with sandblasting room, paint spraying room, drying room, putty room, central dust collection and polishing system, and the introduction of intelligent automatic sandblasting robot (Finland Blastman ) And automatic paint spraying robot, which can meet the painting and spraying requirements of carbon steel cars, aluminum alloy cars and stainless steel cars.
The assembly workshop is responsible for vehicle assembly. Its internal equipment includes: wheeled transport vehicles, four-point weighing equipment, automatic offline machines, assembly platforms, etc. The data terminal is connected to the MES system, and the full production capacity reaches 4 vehicles per day.
The commissioning workshop is responsible for the rain, limit, adjustment, pressure resistance and other bicycle tests of the vehicles, which can realize the static commissioning of the formation of newly-built vehicles and the disassembly and transmission, and can simultaneously meet the static commissioning of 8 trains and 6 two formations of urban rail vehicles Test, equipped with monitoring system and safety warning system to ensure the safety of debugging.