Report on the production of medium-row engines at YaMZ

Original taken fromaltyn73Report on the production of medium-row engines at YaMZ

Yaroslavl Motor Plant just a few days ago turned 100 years old. On this occasion, GAZ Group organized a press tour to Yaroslavl, where it showed not the classic “old” site, where V-shaped diesel engines are made, the one that is 100 years old, but a completely new separate workshop located at a decent distance from the main plant. So welcome to the production of medium-row engines.

The newest engines YaMZ-534 and YaMZ-536 from the YaMZ-530 family belong to the middle row ones. These are the same engines that were developed from scratch with the participation of the Austrian company AVL. The last digit in the index indicates the number of cylinders.

The 4-cylinder engine YMZ-534 is installed primarily on GAZon Next. And it is also used for mid-size LIAZ, KAVZ buses and, of course, is used on the PAZ Vector Next bus unified with the GAZON by aggregates. There are two ecological versions of Euro-4 and Euro-5.Power range - 150-210 hp

"Four cylinder" standardized with 6-cylinder engines. The difference, of course, in the size of the cylinder block. Until recently, these cylinder blocks were supplied from Germany, and now this item is "import-replaced". Such castings were mastered by the foundry shop of the head factory GAZ in Nizhny Novgorod.

The main customers of the 536th motor are Ural trucks. First of all, Ural Next. But also on the "intravolatile" Ural-BB this motor is also installed. It is also used on some versions of MAZ, construction and agricultural machinery. You can meet him on some railway special vehicles and even on small river vessels. Power range - 240-330 hp

A curious diagram from the presentation. Here it is shown how the share of Russian components in these motors has increased and will continue to increase. Even complex components, such as turbo-repressors, are localized.

And now, actually, about the production. Seen it is possible to call the factory-robot. The level of automation here reaches 90%. For example, the crankshaft processing line. The man is not involved at all.At one end, blanks are loaded, a special manipulator moves (with a high speed) blanks from one processing station to the other, and on the other hand, the machined part of the high precision motor comes out.

Preparations for crankshafts were previously produced in Germany, and now the GAZ Group supplies them ... KAMAZ. Yes, here is an unexpected collaboration of direct competitors. These are already ready crankshafts, ready to be sent for assembly.

Another example of automation. Grob Werke automatic machining stations. A person is involved in moving parts, but his task is only to control the manipulator and monitor the machines.

And this, in fact, the main conveyor. I didn’t search for anything — I didn’t find any oil leaks anywhere, nor any dirt at all. The engines are moving slowly, in the shop is incredibly quiet. You can talk almost in a whisper. A very big contrast with the motor manufactures that have been visited before.

On the conveyor, a manual subassembly of some elements is adjacent to full robotization. Periodically assembled motors drive in such “cells”, where a robot-manipulator “conjures” over them. Here, for example, the robot fastens the oil sump.It is curious that the tightening torque of each bolt is entered into the base and in the future all this can be checked by the engine's bar code.

These engines are already ready to be shipped to consumers. In this case, it is YaMZ-536. The capacity of the new production is 20 thousand engines per year, with the possibility of expansion up to 40 thousand. The production plan of the row motors for this year is 15.5 thousand.

And this is another type of production of the new YMZ production site. Engines brand Mercedes-Benz. These are OM646 engines designed for Mercedes-Benz Sprinter low-tonnage vehicles. It turns out that the engines for those Sprinter that are assembled in Nizhny Novgorod are also made in Russia. They do, and do not collect. The head of the block, the block of cylinders and a cam-shaft make in Russia. And these parts are sent not only to Nizhny Novgorod, but also, for example, to Germany as spare parts.

What is in perspective? In the future - the achievement of Euro-6 standards. The GAZ Group plans to launch the production of medium-row engines that meet these standards in 2019. They are not in a hurry with this, as the date of the introduction of these norms in Russia is still unknown. But definitely not before 2020

Very pleasant left impression about the visited production.Frankly speaking, I didn’t even imagine that everything is so high-tech there. And the volume of production of middle row motors is constantly growing. Fortunately, there is a good demand for GAZon / Ural Next trucks.

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