How do diesel locomotives for Railways

Over the past five years, I have visited more than fifty different plants, factories and enterprises. Starting from the largest metallurgical plants, ending with a factory for the production of towels. But I have never had time to rent factories for the production of trains and locomotives. But my son is a fan of the whole train. Therefore, I correct and publish a report on how modern main-line diesel locomotives are assembled in the workshops of the Bryansk Engineering Plant.

1. The Bryansk Machine-Building Plant is the largest enterprise of the domestic transport engineering with a 140-year history. Throughout all time, cars and diesel locomotives became the dominant products. For more than 50 years, BMZ has been a leading supplier of shunting locomotives for Russian railways. In recent years, the team has mastered the production of the first in Russia mainline freight two-section diesel locomotives of the new generation.
The assembly process begins in the cold-press shop, where thousands of necessary parts are cut from sheet blanks on plasma-cutting machines, from the smallest to three meters.Here they are treated and bent in every possible way. This shop is five times the size of a football field.

2. Plasma cutting machines process metal sheets up to 3 cm thick. Plasma cutting is a beautiful and dangerous process. Bright light quickly burns out spots on the camera's matrix.

3. Bending machines. In total, 10 pieces of them are installed in the CPH.

4. In one shift, workshop workers fold up to 2,000 different parts.

5. Main diesel locomotive workshop and frame assembly section.

6. Today about 5 thousand people work at BMZ. The defining occupations in production are welders, turners, millers, machine operators with program control, mechanics of mechanical assembly work.

7. Cut the workpiece is collected in a single frame. This process is called frame laying. Now it takes 16 hours. Nearby is the installation of a new stand, developed by our own engineers, which will reduce the time for laying down the frame by half.

8. The engineering level is represented by designers and technologists. Specialists are constantly working to optimize and improve the equipment assembly plants. Previously, it took up to 10 days to assemble one locomotive frame.In the near future, this process will take 3 days less.

9. Lifting and assembly tilter in action. An indispensable device that allows you to access the frame of the locomotive from all sides.

10. CNC machine for machining the main frame of mainline locomotives. Previously, the processing time of the frame was 32 hours. As a result of the introduction of this machine, it has been halved.

11. Treated surfaces - installation sites of the future diesel generator.

12. The process of transporting the frame in the workshop is similar to the flight of a spacecraft weighing 22.5 tons.

13. Blasting and painting chamber. Here the frames of locomotives are cleaned and painted.

14. And this is a body assembly section. This is the equipment for welding the frame of a diesel locomotive cab. The whole process is similar to the assembly of a large and heavy robot, each of the parts of which weighs several hundred kilograms.

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16. On similar equipment, all sections of a diesel locomotive are assembled: a cabin, a refrigerating chamber, side walls, roof blocks.

17. Side wall in the spray booth.

18. Roof unit over the refrigerator. Each locomotive (more precisely, a section of a locomotive) has two trucks in each of which there are three traction motors installed (do not be surprised, it is an electric one) for each wheel set.An interesting fact is that the engines of the carts that are under the frame are cooled by fans that are far away on the roof of a diesel locomotive.

19. Ready frame of the locomotive cab.

20. The future diesel locomotive 2TE25KM is a mainline freight two-section diesel locomotive with electrical transmission of alternating-direct current with axial thrust control. 90% of the components used in the design of the locomotive - domestic production.

21. This year, Russian Railways will receive 68 such locomotives.

22. View from the refrigerator.

23. At the same time, in the mainline diesel locomotive workshop, up to 10 units of production and 5 frames can be assembled.

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25. Engine room diesel generator.

26. General view of the shop. In the center of the frame under the tent is a new diesel engine, waiting for loading into a diesel locomotive. It is comparable in size to the tractor that brought it.

27. Trolley shop.

28. In each locomotive, up to 60 springs of various sizes are installed.

29. Plot assembly wheel-motor units.

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31. A huge machine, or rather a machining center, designed for machining frames of carriages.

32. It is always nice to see clean and modern production. There is in it its own romance and beauty.

33.These inconspicuous cabinets boxes are in fact high-precision milling machines, which are used for machining the wheels and main gears of the wheel set.

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36. Finished trolley.

37. About 100 liters of oil are poured into each trolley. The weight of one trolley is about 16 tons.

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39. Unlike many other locomotives, all the main nodes of 2TE25KM are easily accessible to service personnel, which greatly increases its maintainability.

40. Each locomotive can hold up to 40 kilometers of various hoses and wires.

41. A 16-cylinder diesel generator 18-9DG with a capacity of 2650 kW produced by the Kolomna plant is used as a power plant. The principle of operation of a diesel locomotive is similar to a heavy dump truck. A diesel engine generates an electric current using a generator, which, in turn, drives the electric motors installed in each wheel (and in this case in each wheel pair). The weight of one engine alone is 16 tons.

42. Each section of the locomotive has its own fuel tank with a capacity of 7 tons. Total 14 tons per locomotive.

43. This is one of the most powerful diesel locomotives in the Russian Railways locomotive fleet.He can drive trains weighing 8 - 9 thousand tons.

44. Compared with its predecessor, the Peresvet diesel locomotive, 2TE25KM is more convenient for the locomotive brigade - there is a general tendency to simplify the controls. “Electronics is simpler here, equipment is easier. The auxiliary circuit was made on-relay, in contrast to Peresvet, where it is on converters that often went down, ”the machinists who conducted the tests of the locomotive share their impressions.

45. 2TE25KM - a new-generation diesel locomotive, not inferior to foreign analogues. According to the plant’s employees, these machines outperform any other mainline diesel locomotives operating in the Russian Federation in terms of their technical and economic characteristics. Speaking in human terms, they work longer, they are easier to repair, and they are effective in terms of fuel consumption.

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