How cars are made for Russian Railways. How cars are made for the Moscow metro. Light and fast – “D” series cars.

Car manufacturing plants are transport engineering enterprises that produce passenger and freight cars for the needs of railways.

In accordance with the technical characteristics, cars produced at car-building enterprises are classified:

by the number of axles (four-, six-, eight-axle, multi-axle);
according to the technology used in the manufacture of the body and the type of material (all-metal, with a body made of light alloys, with metal or wood cladding);
by the structure of the chassis (non-trolley or trolley);
by load capacity;
by load per 1 linear meter of railway track;
by dimensions;
by wagon tare weight;
by axial load.

Car manufacturing plants are replenishing the Russian carriage fleet with four-axle all-metal cars (compartment, reserved seat, interregional carriages, luxury cars), restaurant cars, postal, baggage, mail and luggage cars, and special-purpose cars.

Freight cars produced by Russian carriage-building enterprises are represented by covered cars, flat cars, gondola cars, tanks, isothermal cars, hopper cars, and special-purpose cars (for example, for transporting radioactive waste).

In addition, carriage factories produce self-propelled motor electrified electric train cars, subway cars and diesel trains, tram cars, as well as bogies for passenger cars and wheel sets.

Car manufacturing enterprises have main and auxiliary production. The main workshops include:

car assembly;
casting;
cold-pressed;
forging and pressing;
trolley;
frame-body;
woodworking;
headset

Auxiliary production processes are carried out in the following workshops:

instrumental;
boiler room;
electric power;
motor transport;
painting;
experimental;
mechanical repair;
experimental products.

In modern car building technology, various technological processes are widely used - mechanical, electrochemical, thermal, acoustic, electrical, chemical, etc. New cars are created using economical materials, light alloys, and welded structures. New progressive methods of forging and casting are being introduced into production. Standardization and unification of parts and assembly units ensures their interchangeability.

The history of Russian carriage building began in the middle of the 19th century. The first carriage structures for the Russian railway were created at the Sormovsky, Putilovsky, Kolomensky, Bryansk, St. Petersburg, Verkhne-Volzhsky, Mytishchi plants.

Every time I get to an interesting and large-scale production, I am ready to stay there for days, taking interesting shots, delving into the intricacies of production and technology. It's incredibly exciting.

This is what happened with the Tver Carriage Works. I arrived at them around 10 am, and initially planned to finish in time for the presentation of the new train. But where is it? By two o'clock we had just filmed the workshops where components are produced... and after the presentation we finally got down to the most important thing - the assembly shops. My escorts obviously planned to leave work on time - at 17:00, but, sorry, it’s simply impossible to leave early. As a result, the shooting ended at half past seven, and even then there were still a lot of moments left that could be watched.

And then - another problem. During production I shot over 1000 frames. Defects, repetitions and bad angles were thrown out immediately. By the way, this turned out to be 600-odd frames in the basket. And space was saved. :) Another hundred will be thrown out after a second pass. And then the painstaking work begins: how to choose from the remaining 300 those needed for the post. This is hell, friends, in fact. The fact is that a very complex and multifaceted production was filmed, and I want to show everything. Some shots are needed to understand technical processes, and some are simply beautiful. As a result, I reduced it to 60 pieces. Sorry, we can't do less.

So, after a short introduction - Tver Carriage Works. The largest enterprise in Russia and the CIS for the production of various types of passenger cars and components for them. The main supplier of cars for JSC Russian Railways (and its subsidiary, JSC FPK). The company is part of Transmashholding.

The existing production areas and technological capacities make it possible to simultaneously carry out work on the production of several models of passenger cars, as well as various types of freight cars and special-purpose cars (they weren’t allowed to film in one workshop, they said that they were assembling something secret there).

1. The plant was founded in 1898 by the French-Belgian joint-stock company “Dil and Bacalan” under the name “Verkhnevolzhsky Plant of Railway Materials”. In 1915, it was renamed the Tver Russian-Baltic Carriage Works, and after nationalization (in 1918) - the Tver Carriage Works. In the period from 1931 to the 1990s it was called the Kalinin Carriage Works.

2. From the first years of the 20th century, the era of passenger carriage construction began at the plant. In Tver, four-axle sleeping cars are produced for the joint-stock company “International Society of Sleeping Cars and High-Speed European Trains,” as well as passenger cars of all four classes, double-decker cars, service cars with salons and sleeping compartments, and passenger cars for countries with hot climates. An archival photograph shows a double-decker carriage created at TVZ in 1905

3. The plant has a huge area in Tver, and in fact it is the only large operating enterprise in this city. On the territory you can see buildings of various eras and types. For example, in the photo you see the oldest building - a wooden frame of the water tower of the local boiler house. It has been standing since the 19th century.

4. But we start our tour from the woodworking workshop. Now, in a modern carriage, very little wood is used, but previously almost the entire carriage was made of wood. The wood, or rather the wood board that is currently used, is impregnated with special compounds to prevent combustion and rotting. Alas, this did not happen right away and several large fires, and then tests showed that the old cars burned out in just a few minutes.

But that's how it was. Now the fire safety rules are draconian and the manufacturer is obliged to follow them. Well, the equipment today is not what it used to be, just look at this CNC machine. Replaces more than 8 classic woodworking machines. Parts of any configuration are processed in a matter of minutes, the accuracy is the highest, which accordingly affects the accuracy and speed of assembly of finished cars.

5. Now almost all the internal filling of the car is produced in this workshop. Along with plywood board and fire-resistant wood, plastic, aluminum profiles and other modern materials are used as materials. But the name was kept historical.

6. For example, if I'm not mistaken, these are plastic facing internal panels. They will be installed inside the car on the side walls on top of the double-glazed windows.

7. A worker glues rubber seals to compartment doors with superglue. It’s about half past 12 in the morning, and he’s already used up so many tubes of glue. — I’m a blind tomato and didn’t see that the tubes were full :)

8. The plant has carried out and is modernizing its machine park. The company has a huge number of modern CNC machines. And this picture with the remote control immediately reminded me of this.

9. The machine simultaneously saws four metal profiles, which will later become part of the internal equipment of the car.

10. Now let’s go through and see how the metal parts of the future carriage are made. For example, this part was produced on a press. The bending accuracy is clearly controlled by an inclinometer.

11. This is a sheet of metal after plasma cutting. There are three such installations at the plant. There are 14 more laser complexes for cutting sheet metal. In the foreground: the sides of the cart frames were cut out here. Then there are some other little things. The remaining sheets after cutting will be sent for melting. And back to work. In general, the plant treats metal waste very carefully, and everything goes back to work.

12. Stamping machines. Some small fittings and parts, when the quantity used is large, are not profitable to make using new technologies (expensive and less productive), so they use such a machine park. And next to it stands an old press from very shaggy years. But in absolutely working condition. They decided to keep it in production as a working monument. A kind of “player coach”.

13. Parts are painted with powder paints on an automatic line, but with mandatory visual control and touch-up of complex surfaces with manual sprayers.

14. According to a representative of the plant, even in not the most successful years, great importance was paid to labor protection and the tools and materials used in work. Honestly, it was hard to believe right away, but what I saw in the workshops confirms this.

15. Now it’s time to make the frames for the undercarriages. First, the prepared sheets of metal are joined in special devices and secured by welding.

17. Almost finished cart frame. Since the quality of the trolley and wheel sets is the safety of passengers, the quality requirements are the highest. Moreover, the part is marked with the personal mark of everyone who worked with it. And who checked and controlled. All this data is then stored throughout the operation of the trolley and wheel sets.

18. In the foreground is a stack of bogie frames for the 81-760/761 Oka subway car. TVZ makes them for Metrowagonmash.

19. A very smart trolley frame finishing machine. Special sensors check the overall dimensions and axles. New coordinates are measured from these axes, holes are drilled, and edges are processed. Those. if, for example, the bracket was welded with an offset of a couple of millimeters, then the machine will recognize this and a hole in the bracket will be drilled regardless of this in the right place.

20. Now production of wheelsets. The axle itself is turned on site, and the landing hole (wheel hub) is bored for railway wheels that come to TVZ from various factories, including the Vyksa Metallurgical Plant.

21. Attaching the wheel to the axle. There is a hot and cold nozzle method. Cold is used here. The inner diameter of the hole in the wheel is slightly smaller than the outer diameter of the axle. And the wheel is pressed onto the axle with a given force. The process is recorded by a special control device with a graphical recording of the pressing diagram.

22. Finished wheelsets are sent for bogie assembly.

23. A finished bogie of a new design for a passenger car with disc brakes.

24. And this is the old, familiar trolley design. It is now produced at a neighboring enterprise in Tver.

25. Press for hot forging. It uses special stamps to produce parts of complex shapes from blanks preheated red-hot in gas ovens.

What if it’s complicated? Then the internal cavities are formed using sand models. Previously, they were compacted by hand, and one person could do about a dozen per day, since the work is very painstaking, requires high precision and everything is done by hand. Now sand models are made by machine. The result of her work is in the photo. Every minute and a half, two sand models pop up. And then, after the part hardens, the sand of the model is destroyed on the vibration stand and spills out of the part.

27. The lower part of the flask with the installed sand model.

28. Issuance of cast iron.

29. The ladle is quite small, since a certain temperature of the metal is required to ensure the quality of the casting - a large amount of metal cannot be poured into the flask, the cooling time is limited

30. They manage to fill several flasks and go back to dispensing cast iron.

31. Finished foundry parts and surface treatment.

32. Now let's go look at the body assembly. First, the car frame is welded on special slipways. Undercarriage equipment is installed and communications are laid.

33. In parallel with the assembly of body frames, car sidewalls are manufactured on a special line. The assembly and welding process is as automated as possible and is carried out with minimal human intervention.

34. The roof sheathing is first welded flat, then turned over and given a semicircular shape on a special stand. The arches are welded and the roof takes on shape and rigidity.

35. Finally, all parts of the body (frame, sides, end walls and roof) are connected together into a finished product - the basis of the future carriage.

36. First, all incoming components and parts are tacked.

38. That's it, the carriage is almost ready. At least its frame. As you can see, even a heater (or rather, a boiler) is already installed here.

39. The car after applying the thermal insulation coating and flooring.

.::clickable::.

41. Assembly is carried out at positions - only certain actions are performed at each. Then the car moves to the next position. They come here already painted.

42. The car after installing almost all internal systems. Now it’s time to install partitions and mount what the passenger will ultimately see.

.::clickable::.

43. The plant is the main supplier of passenger cars for the subsidiary of Russian Railways - the Federal Passenger Company. But the company's product range is very extensive.

.::clickable::.

44. New carriages with seats are now included in permanent trains, including branded ones.

45. The full production cycle of a wagon takes about 70 days. For a double-decker carriage this figure is about 100 days. This is the period from the manufacture of the first part to the finished car. On average, a car spends 12 days in the car assembly shop directly assembling the finished product.

46. The main (left) line is occupied by serial cars for Russian Railways. On the middle one this time there were staff and dining cars. And the right line is occupied by other projects. At the time of filming, these were sleeping cars for international traffic (RIC size) - a joint project of TVZ and Siemens.

.::clickable::.

47. And cars for the railways of Kazakhstan.

48. Since 2008, 2,800 different cars have been supplied for the needs of Russian Railways. These new cars are used as a priority for the formation and renewal of branded and fast trains.

.::clickable::.

49. I won’t show you an ordinary compartment carriage, and there are already a lot of photographs. But the presence of an outlet in the compartment is very pleasing.

50. And this is a lift for the disabled in the staff car.

51. There is a special compartment and toilet for them only in this carriage. Look how the passage has been widened so that the stroller can pass through.

And the service life of a stainless steel car is 40 years versus 28. By the way, I learned a secret at the plant that had been bothering me for a long time. You see the inscription “mileage - 450” on the end of the car. This means that an additional metal layer of increased strength is deposited on the surface of the automatic coupler and buffers, which ensures that the cars can run for at least 450 thousand km without replacing these wearing parts.

53. Double-decker car developed at the initiative of Russian Railways. So much has already been written about him that I won’t go into detail. The photo shows the first prototype, a prototype on which the plant tested and mastered the design and technology of this innovative product. To the credit of the plant, it must be said that this prototype was manufactured in just 8 months from the start of design - from the first line on the drawing. There are few competitors, even on the world market, capable of putting into production a completely new product in such a short time.

54. The first metro car produced at the plant. At first, “Oka” was assembled in Mytishchi, then part of the order was sent to Tver. It was done. Now at TVZ they only make frames for metro trolleys.

55. Sleeping cars of RIC size for international services - a joint project of TVZ and Siemens commissioned by Russian Railways. Pay attention to the wide surfaces of the end accordions.

56. Let’s take a closer look at this carriage. Coupe - in general, everything is familiar.

57. And this is how the door from the compartment opens. It is surprising that it is mirrored from the inside, but when open it blocks the passage. Not a very successful design solution, in my opinion, although the design was developed by one of the grandees of the world carriage building - the Siemens company.

58. Each carriage has a shower.

59. And the washbasin under the table. But there is no opener under it. :)

60. Panorama of the plant. Motor transport workshop and railway lines with finished products. Behind the scenes were paint shops, a climate testing station, a central factory laboratory and much more. But there are already a lot of photographs. And by 2030, Russian Railways will purchase 16.5 thousand cars for 774.5 billion rubles, of which 2 thousand in the next three years.

.::clickable::.

Many thanks to the press service of the Tver Carriage Works and all its employees for their patience and help in preparing the material!

Taken from russos in How cars are made for Russian Railways

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Today we will visit the Mytishchi Metrovagonmash plant and see how the enterprise works, which has been producing cars for the Moscow metro for more than 80 years. What other products does the company produce that we saw at the plant last time? And today we will have an interesting walk around the territory and workshops of the plant. I admit, I have long wanted to come here, as I am interested in the topic of the Moscow metro. I’ve seen more than once how new metro stations are built, and I’ve also seen where trains sleep and are repaired. To fully disclose the topic, it was not enough just to see how these very trains are assembled. It’s very cool that it has now become possible to get behind the fences of enterprises and organizations whose doors are usually closed to ordinary visitors. Although in small groups and not on a permanent basis, enthusiasts conduct excursions to interesting enterprises. This time, the “Industrial Train” project helped me get to the Metrovagonmash plant, for which special thanks to them. Well, let's get closer to the point. Moreover, on the day of our visit, carriages of the new Moscow train were being assembled in the workshops of the enterprise, and we also managed to see for the last time the buildings of the historical workshops of the 19th century, which were demolished literally the next day...

1. We arrive at the Mytishchi station and climb onto the pedestrian walkway above the tracks. From here you can see the water tower. Look how beautiful it is! A pearl of architecture in Mytishchi, which in general is not particularly rich in architectural monuments.

2. Another tower. She is also on the territory of the plant.

3. We walk along Kolontsova Street along the old buildings of what was once a carriage repair plant. There is a banner like this hanging on the wall.

4. Opposite the entrance there is a bust of Kolontsov himself. What’s interesting is that the bust was cast right here at the factory by one of the workers, a non-professional sculptor. It is clear that Kolontsov also worked here at the Carriage Repair Plant.

5. The administrative building is a modern, non-historical building; it has apparently been renovated, lined with composite panels and modern windows installed.

6. There is another monument in front of the entrance. This is the SU-76 self-propelled gun. The inscription on the pedestal reads “In memory of the labor feat of the staff of the Mytishchi Machine-Building Plant during the Great Patriotic War of 1941-1945.”

7. And another one is not even a monument, but an art object. This is a stylized "I" type carriage. It’s not for nothing that this particular car is on the pedestal; at one time its design was very progressive. For example, the car body was made of light aluminum. But the fire at the metro station "Paveletskaya" gave up on aluminum in 1987 and the car never entered the line.

8. A modern renovation was done inside. This is great. I expected to see a typical Soviet interior here. But no. Everything looks modern - Metrovagonmash shows guests that the enterprise has entered the 21st century. There is graffiti on the wall with a “Moscow” carriage - cool!

9. We go into the territory.

10. As always at large old enterprises, there is so much on the territory. A bunch of all sorts of buildings, the purpose of which only the locals know.

11.

12. Of course there is a board of honor. I wonder if in Soviet times these three “sticks” were red? Now they are painted in tricolor.

13. Is there also an “I” type carriage on the emblem?

14. Let's move on. The blacksmith shop is in a historical building, although, as you can see, it was later completed, or rather built on.

15. And then there is the architectural pearl of the plant - the historical workshops. Look how beautiful it is.

16. On the right are the buildings along which we walked from the station.

17. Amazing thing. No work has been carried out here for a long time; the buildings are idle. What do you think the plant management decided to do to make a profit from this area? Do some minor renovations and rent out these beautiful premises, as is done in Moscow, for example on or? Or maybe they decided to organize a transport museum on the basis of these stunning premises in order to have a constant income and make the city of Mytishchi attractive for tourists? No, why! The management decided to simply... demolish these buildings.

18. I don’t understand how this is possible now. How can a hand be raised to demolish a historical building?

19. We were lucky and our excursion took place on the eve of demolition.

20. Demolition began precisely from the historical facades, this suggests that it was a conscious decision. Someone took sin on their soul and made this decision.

21. It's a pity.

22. On the territory of the plant we meet such an interesting specimen.

23. This is a rail bus, yes, yes, there are those. RA-1.

24. This car was created on the basis of the Yauza metro car.

25. Almost everywhere there are posters on the theme of the new Moscow carriage. It looks especially surreal on old houses like this.

26. The Yauza River flows through the territory of the plant. Here she is.

27. And here are the new workshops. This is where we will go. It is interesting that historically, the assembly shop had the number 17, and now all modern assembly shops also have the number 17 in their markings. That is why the shops here have numbers 217 and 317.

28. Let's see where the "Moscow" type carriage begins.

29. The x car is assembled from separate parts.

30. First, individual elements are collected, and then enlarged here. Look, all these welding points are places where reinforcing elements are welded.

31. Remember Hedgehogs and Numbered Ones? They have stiffening ribs located on the outside. Now the ribs are hidden inside. The outer walls are smooth, but the power elements that run along the car cannot be divided anywhere, they were simply placed inside.

32. It was nice to see that the workshops were very clean and bright. This is without a doubt a modern production.

33. Working moments.

34. Section where doors are installed. Some kind of element with wheels.

35.

36. Look how clean it is.

37. Assembling a carriage is manual work. Real handmade.

38.

39. Again. all the workers are in clean new overalls, the equipment is all new and modern. This attitude towards workers is a good sign. This means management doesn’t care about the workers.

40. On the left, as I understand it, is the upper part of the carriage.

41.

42.

43. In addition to modern equipment, there are also such rarities.

44. Carts.

45. Very interesting.

46. Here's another interesting element. This is a mask. Cool! It is apparently made from composite materials.

47. A few working moments.

48. Assemble a laser machine for cutting materials other than metal.

49. And this one is for cutting metal.

50. People at work.

51. Sheets of metal from which the necessary parts were cut.

52. I don’t know what it is, probably abs.

53. I love these things, they look very impressive.

54. We go out for a little walk in the air. There is such a thing here that drives along the façade of the assembly shop and transports cars.

55. Fashionable orange color.

56. For winter, the installation is equipped with such a blade.

57. It’s very positive inside... because of the color of the plastic that was used to line this installation.

58. On the opposite side are semi-finished products.

59. When the assembly of the carriage is completed, it is placed on trolleys and the carriage is ready.

60.

61. Wheels.

62. An amazing place, of course.

63. There are cool pictograms on the gates.

64.

65. Here is another transport vehicle, but without a cover.

66. Look, here they are installing a mask on the carriage.

67. But the finished carriage was packed in film.

68. Now let’s see where the cars are primed and painted.

69. After the carriage is welded, it is sent here for painting. To begin with, the body is primed.

69. Here you can look at the carriage without “clothes”. For me, as an engineer, this is very interesting.

70.

71. An accordion will appear here later. Almost all parts of the car are angular, with rounded lines only here, in the accordion area.

72. The process of painting a carriage lasts two days.

73. This is how he will become in the end. The coloring is not the most beautiful, it seems to me, but it matches the brand beech.

74. Freshly painted carriage, what could be better.

75. Shines.

76. The painting booths are huge, this is not surprising, since the entire car must fit into the chamber. All equipment is foreign. They asked the plant representatives, but what about domestic products? They say that they have tried using domestic tools and equipment, but they do not provide the reliability and quality that foreign tools provide. So it goes.

77. Paint shop.

78.

79. Now let's move to the assembly shop. The painted carriage comes here, as well as the rest of the parts that need to be installed in this beautiful iron box. Here's a whole pallet of seats.

80. There are carts right there...

81. Beauty.

82. The assembly shop is the most spectacular.

83. The car stands on a stand so that it is more convenient for workers to assemble it, and only at the end of the assembly is the car placed on trolleys.

84. Accordions. It is interesting that the system that fixes the accordion on the car body is similar to the locking system of modern aluminum or plastic windows; there are rods along the perimeter and corner gears are located in the corners. There are fixing elements on the rods. As I understand it, this was done in order to quickly install and remove the accordion.

85. There is order at each assembly site. The parts that need to be installed are laid out on the floor, next to it is a reminder about how and what needs to be installed. This is great.

86.

87. High production culture is the key to high-quality assembly.

88. In addition, additional information can be obtained at such a terminal.

89. Everything is clean and tidy everywhere.

90. Look how many wires need to be installed.

91. That's true.

92. It’s very nice that the manager talks so enthusiastically about his enterprise. This, like cleanliness and order, is a good sign; it means everything is fine at the enterprise.

Now we know how and where, under what conditions, the newest trains for the Moscow metro are assembled. When asked whether work is underway to develop the next model, we were answered in the affirmative. As I understand it, this will not happen soon, but it’s still nice that the work is going on.

This is what happened with the Tver Carriage Works. I arrived at them around 10 am, and initially planned to finish in time for . But where is it? By two o'clock we had just filmed the workshops where components are produced... and after the presentation we finally got down to the most important thing - the assembly shops. My escorts obviously planned to leave work on time - at 17:00, but, sorry, it’s simply impossible to leave early. As a result, the shooting ended at half past seven, and even then there were still a lot of moments left that could be watched.

4. But we start our tour from the woodworking workshop. Now, in a modern carriage, very little wood is used, but previously almost. The wood, or rather the wood board that is currently used, is impregnated with special compounds to prevent combustion and rotting. Alas, this did not happen right away and several large fires, and then tests showed that the old cars burned out in just a few minutes. But that's how it was. Now the fire safety rules are draconian and the manufacturer is obliged to follow them. Well, the equipment today is not what it used to be, just look at this CNC machine. Replaces more than 8 classic woodworking machines. Parts of any configuration are processed in a matter of minutes, the accuracy is the highest, which accordingly affects the accuracy and speed of assembly of finished cars.

6. For example, if I'm not mistaken, these are plastic facing internal panels. They will be installed inside the car on the side walls on top of the double-glazed windows.

7. A worker glues rubber seals to compartment doors with superglue. It’s about half past 12 in the morning, and he’s already used up so many tubes of glue. - I’m a blind tomato and didn’t see that the tubes were full :)

8. The plant has carried out and is modernizing its machine park. The company has a huge number of modern CNC machines. And this picture with the remote control immediately reminded me of this.

9. The machine simultaneously saws four metal profiles, which will later become part of the internal equipment of the car.

10. Now let’s go through and see how the metal parts of the future carriage are made. For example, this part was produced on a press. The bending accuracy is clearly controlled by an inclinometer.

13. Parts are painted with powder paints on an automatic line, but with mandatory visual control and touch-up of complex surfaces with manual sprayers.

15. Now it’s time to make the frames for the undercarriages. First, the prepared sheets of metal are joined in special devices and secured by welding.

18. In the foreground is a stack of bogie frames for the subway car 81-760/761 “Oka”. TVZ makes them for Metrowagonmash.

20. Now production of wheelsets. The axle itself is turned on site; for railway wheels, which come to TVZ from various factories, including from, the landing hole (wheel hub) is bored.

22. Finished wheelsets are sent for bogie assembly.

23. A finished bogie of a new design for a passenger car with disc brakes.

24. And this is the old, familiar trolley design. It is now produced at a neighboring enterprise in Tver.

25. Press for hot forging. It uses special stamps to produce parts of complex shapes from blanks preheated red-hot in gas ovens.

26. Now let’s go to the foundry. In this nondescript photo you see a literal technical revolution in the foundry business. If you need to cast a simple part without cavities inside, then it’s all simple. But what if the part is complex and there are cavities and channels inside? There are two options. In the first case, a wax internal model is placed inside the flask. It gives the internal structure and when the metal is poured, it melts and flows out. But you can do simple things this way. What if it’s complicated? Then the internal cavities are formed using sand models. Previously, they were compacted by hand, and one person could do about a dozen per day, since the work is very painstaking, requires high precision and everything is done by hand. Now sand models are made by machine. The result of her work is in the photo. Every minute and a half, two sand models pop up. And then, after the part hardens, the sand of the model is destroyed on the vibration stand and spills out of the part.

27. The lower part of the flask with the installed sand model.

28. Issuance of cast iron.

30. They manage to fill several flasks and go back to dispensing cast iron.

31. Finished foundry parts and surface treatment.

32. Now let's go look at the body assembly. First, the car frame is welded on special slipways. Undercarriage equipment is installed and communications are laid.

34. The roof sheathing is first welded flat, then turned over and given a semicircular shape on a special stand. The arches are welded and the roof takes on shape and rigidity.

35. Finally, all parts of the body (frame, sides, end walls and roof) are connected together into a finished product - the basis of the future carriage.

36. First, all incoming components and parts are tacked.

38. That's it, the carriage is almost ready. At least its frame. As you can see, even a heater (or rather, a boiler) is already installed here.

39. The car after applying the thermal insulation coating and flooring.

.::clickable::.

41. Assembly is carried out at positions - only certain actions are performed at each. Then the car moves to the next position. They come here already painted.

42. The car after installing almost all internal systems. Now it’s time to install partitions and mount what the passenger will ultimately see.

.::clickable::.

43. The plant is the main supplier of passenger cars for the subsidiary of Russian Railways - the Federal Passenger Company. But the company's product range is very extensive.

.::clickable::.

44. New carriages with seats are now included in permanent trains, including branded ones.

47. And cars for the railways of Kazakhstan.

49. I won’t show you an ordinary compartment carriage, and there are already a lot of photographs. But the presence of an outlet in the compartment is very pleasing.

50. And this is a lift for the disabled in the staff car.

51. There is a special compartment and toilet for them only in this carriage. Look how the passage has been widened so that the stroller can pass through.

52. Now all bodies are made of stainless steel. The last production car made of ordinary carbon steel is on display at the plant's exhibition site. Occasionally, if the customer wishes, the plant fulfills orders for cars using old technology. But for the customer this is a double-edged sword. The difference in the price of a car with a stainless steel body and a regular one is less than a million rubles. And the service life of a stainless steel car is 40 years versus 28. By the way, I learned a secret at the plant that had been bothering me for a long time. You see the inscription “mileage - 450” on the end of the car. This means that an additional metal layer of increased strength is deposited on the surface of the automatic coupler and buffers, which ensures that the cars can run for at least 450 thousand km without replacing these wearing parts.

55. Sleeping cars of RIC size for international services - a joint project of TVZ and Siemens commissioned by Russian Railways. Pay attention to the wide surfaces of the end accordions.

56. Let’s take a closer look at this carriage. Coupe - in general, everything is familiar.

58. Each carriage has a shower.

59. And the washbasin under the table. But there is no opener under it. :)

Many thanks to the press service of the Tver Carriage Works and all its employees for their patience and help in preparing the material!

How cars are made for Russian Railways. How cars are made for the Moscow metro. Light and fast – “D” series cars.

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