New workshop in the Anisovka motor car depot
A modern overhaul workshop with a closed electric train wash has been put into operation at the Anisovka motor car depot on the Volga Road.
The design capacity is 150 sections (300 wagons) per year, which will make it possible to service AC electric trains not only on the Volga railway, but also on other highways. The total estimated cost of construction was over 700 million rubles. The annual economic effect will be 46 million rubles.
The new complex is equipped with high-tech equipment for repairing components and parts of rolling stock, modern diagnostic systems for detecting various types of car malfunctions.
Since 2006, the Anisovka depot has been operating a car washing complex jointly produced by the UES member states, designed for outdoor washing of electric trains, passenger cars and rail buses. It takes 40 minutes to fully process one composition, and 4-5 compositions can be taken during a change of "showers". Electric trains move with the help of a shunting device that pulls it at a speed of 1 km/ h through a room equipped with irrigation installations, brushes, and a dryer. All this happens automatically, without the involvement of an auxiliary locomotive and manual labor. Reducing the downtime of an electric train during maintenance is facilitated by the possibility of cleaning bio toilets at the same time as washing electric trains.
A sanitary and household complex with dry cleaning for clothes, modern showers and a dining room with 40 seats has been put into operation for the repair staff.
Prior to the introduction of the new repair shop, TP-2 TP 3 were carried out using the large-scale method. Traction engines were updated at the Tantal plant in Saratov, trolleys of trailed and lead cars of electric trains, coupling devices, air hoses and pneumatic devices — at the Saratov wagon depot I. Major repairs of wheel sets of trailed cars were carried out at the Sarepta depot of the Volgograd region, and motor cars were repaired, taking into account the route to the factory and back was 1.5 — 2 months.
The new workshop with its production facilities will allow performing routine repairs of TP-2 and TP-3 electric trains of any series of alternating current, as well as repairs with replacement of elements of individual components of the main equipment of motor-car rolling stock of Privolzhskaya and other roads of Russia.
The Anisovka motor car depot was built in 1974. Now the company has been separated from the locomotive industry into the independent Anisovka motor car depot, a division of the Road Directorate for Passenger Services in Suburban Traffic, a structural enterprise of the Volga Railway, a branch of Russian Railways.
During the depot's existence, diesel locomotives, electric locomotives, DC and AC electrical sections were repaired here. When receiving new series of rolling stock, the depot staff has always successfully mastered the technology of maintenance and repair of locomotives and MVPS. The TR-3 technology was also successfully mastered in 1993, and the KR—1 technology of electrical sections was developed in 1996.
The company pays special attention to ensuring train safety. New equipment and advanced technologies are being systematically introduced into the depot. The resulting electronic equipment has software that allows you to create databases for a qualitative analysis of the operation of components and assemblies of electric trains.
The management of the road pays great attention to the external and internal appearance of the enterprise, assisting in the technical re-equipment of its repair base under the program of retrofitting the motor car depot to the requirements of the regulations.
The company's assigned fleet consists of electric sections ER9T, ED9T, ED9M and ED9MK (with an average service life of 12.5 years) and rail buses RA1 (since 2005), as well as diesel locomotives CHMEZ for shunting work in the depot.
The construction of a new workshop for the current repair of electric trains at the Anisovka depot was started in 2003. The workshop includes:
- stall section for 7 electric train cars;
- trolley shop with one washing machine and two positions for disassembly and assembly of trolleys of electric trains;
- pantograph repair department (pantograph balcony);
- a workshop for the repair of wheelsets with a change of elements, designed for a repair program of 3,000 — 3,500 wheelsets per year;
- electric machine department
- auto brake equipment repair department,
- paint department.
Disassembly and assembly of wagons are carried out at seven positions of the stall part of the workshop. They are equipped with UDS-160 jacks and overhead cranes with lifting capacities of 10 and 16 tons.
There are two positions for disassembly and assembly of trolleys. Both positions are unified and provide for the disassembly and repair of both motor and trailer trolleys. They are equally equipped with a mechanism for moving trolleys, wrenches, jacks and special devices for removing TED, wheel sets and cradle suspension.
The washing machine for washing trolleys MC0102.0.00.00 is designed for washing trolleys and their frames with water jets without the use of special solutions, under high pressure (150 bar). Cleaning is achieved by moving water jets throughout the truck, which allows the surface layer to be washed off, including impurities, oxides, rust and peeling paint, as well as remnants of petroleum products. Cleaning is carried out in a closed washing chamber without the presence of an operator.
The wheel shop has two wheelset repair departments. In the first one, there is a production line for the ordinary inspection of electric train wheelsets. The department is equipped with the following technological equipment:
- a stand for disassembly and assembly of wheel-gear units of MM234 electric trains with a crane with a lifting capacity of 0.5 tons. It is designed for disassembly and subsequent assembly of traction gearboxes during the dismantling and installation of wheel sets.;
- disassembly stand for the upper gearbox housing MM239, designed to rotate it during disassembly;
a stand for disassembling the lower half of the MM233 gearbox housing, designed to rotate it during disassembly;
- a workplace for removing and installing the elastic coupling MM240, designed to rotate the gearbox housing during disassembly and installation of the elastic coupling;
- a stand for pressing out axle box bearings, designed for removing axle box housings from the wheelset and pressing out axle box bearings;
- roller bearing washing machine MS0001.02. Roller bearings are washed with hot water without the use of cleaning solutions;
- a washing machine for washing the housings of the box MSO 001.02. Cleaning is achieved by moving jets of hot (up to 70 ° C) water throughout the body of the box, which allows flushing the surface layer, including contamination;
- a washing machine for washing the wheelsets of motor and trailer wagons MC0001.02. Cleaning is achieved by moving water jets under high pressure while simultaneously cleaning the middle part of the axle with metal brushes;
- a magnetic flaw detection stand for wheelsets. It is carried out in a dry way using MD12 flaw detectors. An ultrasound check is also performed here with the UD-2-102 "Peleng" flaw detector.;
- a complex for mounting axle boxes on the axles of wheelsets of YALUK442313.007 wagons. The complex consisting of two manipulators with suspension and air distribution structures is designed for planting axle boxes on the axles of wheelsets of wagons using small-scale mechanization. The suspended balanced manipulators of the complex, manually moved along the monorails, allow you to grab and carry both cargo and (with minor readjustment) passenger boxes. Manipulators can also be used when removing axle boxes from a wheelset.;
single-column hydraulic press with a force of 2500 kN PB6334-02. This mechanism refers to a universal type of equipment for performing various pressure treatment operations. The main operations performed on the press are assembly and pressing, stamping, stitching and calibration;
- two vibration diagnostic stands for MM231 electric train wheel-reduction units. They are designed for unwinding wheel-gear units of electric trains with jaw and leash axles during diagnostics.;
- elastic coupling flange lapping stand A2070.150. The seats of the elastic coupling flanges are lapped on it before installation.
In the second department of the wheel shop, a complete inspection (overhaul) of the wheelsets is carried out. It is equipped with the following equipment:
- a specialized wheel-rolling machine 1836M.10. It is designed for turning wheelset bands with rolling out from under electrical sections.
- a hydraulic pressure nozzle with a force of 6.3 MN PA6738. Wheelsets, as well as other parts, are pressed and pressed on it.;
- turning and rolling machine KZH1842.02. It is designed for turning and knurling the necks of the pre-tread and riser parts of the axles of diesel, electric and wagon wheel sets.;
- a special knurling machine KZH1844. On it, the outer necks, rolls and pre-tread parts of the carriage axle are rolled with the axis of rotation of the rolling rollers rotating in the process.;
- a 4 MN P6736 hydraulic attachment press for pressing and pressing wheelsets, as well as other pressing operations within its technical characteristics;
- 2K522 radial drilling machine, designed for processing holes at various angles in small, medium and large parts. Drilling, reaming, countersinking, unfolding, threading in different planes and at different angles can be performed on the machine.;
- the ZM175 semi-automatic circular grinder for mortise and longitudinal grinding of external cylindrical and flat conical surfaces in single, serial and large-scale production;
