20 1410 Р.Р.Р.

Plane-like coaches

TEP70BS diesel locomo-tive: modern, powerful, economic

Igor Malakayev on Transmashholding digitization

NOISELESS JOYRIDEAROUND BUDAPEST

Billy69150/commons.w

ikimedia.org

MA

GA

ZIN

E FO

R P

AR

TNER

S№

3 1

0/20

18

4P.

No.3 10/2018TABLE OF CONTENTS

1

14

10

420

1

4

10

14

20

NEWS

TOPIC OF THE DAYUpgraded trains deployed in Budapest metro

PREMIERENew diesel locomotive TEP70BS knows no obstacle

OPERATIONUnique “tourist” coaches for Siberian expanse

INTERVIEWIgor Malakayev on digitization processes at Transmashholding

OUTLOOK? EXCELLENT!

The certificate presentation took place at the InnoTrans-2018 trade show in Berlin. The ceremony was attended by Andrey Solovyov, General Director [CEO], OAO Tverskoy Vagonostroitelny Zavod [Tver Wagon Works] (TVZ), Dmitry Shpadi, deputy head, Federal Rail Agency, and Aleksandr Karyakin, first deputy head, Rail Certification Register. The certificate is valid for five years and authorizes the manufacture of 48 five-carriage trains and the operation of rolling stock on public tracks.

The EG2Tv electric train has been developed on a new one-size-fits-all platform that anticipates a whole family of rolling stock (6+6) that is designed for various operating environments and expected to appear before the year is out. In terms of engineering solutions, comfort and cost-effectiveness, Ivolga electric trains hold their own against the best Russian- and foreign-made comparables, and even surpass them in certain ways. The train was designed with the involvement of a leading European transport design firm. The spacious passenger compartments have stand-alone microclimate and air disinfection systems. The electric train is suitable for the carriage of passengers with reduced mobility and passengers with children. It has wide doors (1400 mm) and passages that

accommodate wheelchairs; spacious toilet rooms with accessibility options.

There are also wheelchair racks. Ivolga has high local content, in excess of 90%.

The life-cycle operation cost of the electric train is 20% lower than that of mass-produced trains. 30% savings are achieved through the lower cost of mandatory periodic maintenance and scheduled repairs. Also, energy-saving equipment reduces electricity costs by 30%.

Transmashholding has obtained a certificate of conformity for the Ivolga EG2Tv upgraded electric trains. They will be carrying passengers on the Moscow railway thoroughfares.

DMITRY SHPADI, deputy head, Federal Rail Agency:

- The Ivolga train is fully consistent with the global trend towards the development of intermodal carriage, which is a major driver of transport system performance improvement.

1

NEWS

INCIDENTALLYTransmashholding has custom-developed an innovative family, Ivolga, for Moscow intermodal carriage (with Moscow railway thoroughfares to be a central component of it). The new electric trains will have USB ports to charge electronic devices, bicycle racks and extra lighting fixtures in the entrance lobbies. For the first time there will be introduced an automatic passenger count system, the toilet rooms will receive touch taps, soap dispensers and hand dryers. There will be a significant increase in the number of handrails; they will be warm to the touch. The train software will be upgraded, which will enable TV broadcasting in the compartments.

Magazine for partners of Transmashholding JSC

Editor-in-chiefKonstantin Nikolayevich Dorokhink.dorokhin@tmholding.ru

Editorial office address:127055, Moscow,ul.Butyrsky Val, 26, bld. 1Phone: 8 (495) 660-89-50

The magazine was prepared in cooperation with FuturaMedia LLCwww.medialine-pressa.ru

General Director Larisa Rudakova

Signed for printing: October 23, 2018 Printed in Mediacolor printing house: Moscow, ul.Volnaya, 28Circulation: 999 copies.

Distributed for free

№ 3 10/2018MAGAZINE FOR PARTNERS

Transmashholding has made a contract to purchase TOO Tulpar Talgo, a Kazakhstan-based rail car assembler. Concurrently, a contract was signed for to Tulpar Talgo to supply in 2018-2026 1200 coaches to AO Passazhirskiye Perevozki [Passenger Carriage JSC] (a subsidiary of AO NK Kazakhstanskiye Zhelezniye Dorogi, Kazakhstan's national railway operator),

Signatures to the contract were affixed by Kirill Lipa, CEO of

Transmashholding, and Kanat Alpysbayev, Chairman of the Management Board, AO NK Kazakhstan Temir Zholy.

The Russian company will own more than 99% of Tulpar Talgo.

In accordance with the arrangements in place, Kazakhstan will be making state-of-the-art coaches designed by Transmashholding, with and without compartments, staff coaches and restaurant cars.

EXPLOSIVE GROWTH Transmashholding's sales up 67% in 1H2018.Sales of metro cars have increased dramatically, by 160% (from 120 to 312 units). Repairs were also up - 173%. The passenger segment also saw higher sales of locomotive-pulled coaches (up 53%, 377 vs 246); commuter train coaches (up 53.5%, from 99 units to 152). Sales were much higher for diesel engines across the board (up 126%, 120 units vs 53). The total number of passenger, shunting and cargo diesel locomotives delivered to customers was up 13% (190 units vs 168). An upward trend is seen in the segment of electric locomotives: their sales are up 53% (223 units vs 146).

In the 1st half of 2018, Transmashholding unveiled a modified AC-powered train (the

version for Russian Railways; previously supplied to Kazakhstan). The group has developed a special version of the traction motor NP1 for a Russian industrial undertaking. Efforts are in progress to manufacture Ivolga electric trains designed for Moscow railway thoroughfares (MRTs) New three-unit diesel locomotives, ZTE25K2M, were developed for BAM [Baikal-Amur Mainline]. Yermak, a modified ZES5K electric locomotive, appeared. A passenger diesel locomotive was built, TEP70BS, with a two-wire power supply system, and certified.

COMPREHENSIVE APPROACHUWC and Transmashholding to join forces to grow haulage in South America.The research, development and manufacturing corporation Obyedinennaya Vagonnaya Kompaniya [United Wagon Company] and Transmashholding inked a cooperation agreement on rail haulage. The document provides for cooperation in organizing packaged supply of haulage solutions, including Transmashholding locomotives, as well as goods wagons and components made by UWC to Argentina, Uruguay, Bolivia and Paraguay. Cooperation will be based on the financial-industrial infrastructure being put in place in Argentina by TMH Argentina, a subsidiary of TMH International AG.

The current fleet of South America is about 145 thou. freight wagons. The region mostly uses AAR (Association of American Railways) standards, track

gauges 1000, 1067, 1435, 1600 and 1676 mm. The projected demand for goods wagons is 4.5 thou. u. per year due to the construction of railways to export commodities.

FRANCO COMPARATO, CEO, TMH Argentina:- We believe in the bright future of the transport market in Argentina and Latin America at large. Transmashholding seeks to expand the range of the products and solutions that we could sell in the countries of South America.

MAKSIM KUZEMCHENKO, deputy general manager for business development, UWC:- The Latin American market will soon boom due to higher production and faster development of new deposits of minerals and other resources. I am confident that cooperation in the region will be a success and that customers will appreciate the quality and the benefits of our technology.

The merger between Transmashholding and LocoTech reflects the general trend towards integration, typical of global mechanical engineering in recent years, and is aimed at improving their competitive capacity in the global market. Also, it will enable putting together a full-value offer of locomotives for Russian Railways under life-cycle contracts; increase the manufacturer's export potential through after-sales service. The pooling of the companies' research and development potential will pave the way for improving R&D investment performance and reducing time-to-market.

STRENGTH IN UNITYTransmashholding and Locotech-Service shareholders pool shares and equity interests to improve management and long-term growth.

EGYPTCHOOSES THE BEST!Transmashholding Hungary Russian-Hungarian consortium to supply 1300 railway coaches to Egypt National Railways.

A contract to this effect was signed in Cairo on September 25. Signatures to the document were left by Sergo-Shakhzada Kurbanov, vice president of Transmashholding, and Ashraf Raslan, head of Egypt National Railways (ENR).

The contract was awarded to Transmashholding Hungary Kft. Russian-Hungarian consortium in response to an invitation to tender issued by ENR in 2017. Tenders were also submitted by manufacturers from China, Italy, India, Spain and Rumania. The total value of the rolling stock to be made for Egypt exceeds 1 bln euros. The supply contract is for 5 years.

Within the consortium, OAO Tverskoy Vagonostroitelny Zavod [Tver Carriage Works] (TVZ) will be the key manufacturer of components, responsible for the technology transfer and production engineering. OOO TMKh Engineering will be the lead developer responsible for technical audit. The Hungarian side will serve as an industrial and financial partner. Half of the coaches will be made by Hungary's Dunakeszi Járműjavító Kft. in coordination with TVZ; the rest will be the responsibility of the Tver manufacturer.

A portion of the order will be supplied as individual components for final assembly by a local manufacturer to be set up in Egypt by TMH International AG in partnership with the Egyptian National Organization for Military Production.

COACHES FOR KAZAKHSTANTransmashholding signs contract to purchase Tulpar Talgo and to supply 1200 railway coaches to Kazakhstan.

The company's equity is spread between a group of Russian businessmen and the French firm Alstom Holdings. Alstom Holdings, which used to own 33% of Transmashholding, has been allocated 20% in the new entity.

The companies owned by Iskandar Makhmudov, Andrey Bokarev, Dmitry Komissarov and Kirill Lipa received 79.4% in the new entity. Dmitry Komissarov and Kirill Lipa are the controlling shareholders.

At the same time, Transmashholding and Locotech-Service will retain their corporate identities. Headed by general director Kirill Lipa, the management will continue running the Transmashholding group; Yury Degtyaryov and his colleagues will keep their executive positions at Loko-Tech. The shareholders plan a gradual operational integration to result in the group becoming No. 4 in the world by sales among the groups specializing in the development, production and maintenance of rail rolling stock. At year-end 2017, the aggregate sales of the two corporate groups was about 260 bln rbl.; it is projected to exceed 320 bln rbl. this year.

CORPORATE NEWS

32

No.3 10/2018

Transmashholding-upgraded trains account for 46% of Budapest metro’s entire fleet

were supplied to Budapest

37 trains

underwent extensive modernization (185 of type 81-717/714, 10 of type

81—717/714-2M and 27 of type Ev3)

222 COaCHEs

is the service life of upgraded coaches

25 YEars

have been cut the costs of equipment maintenance and repair after

refurbishment

20%BY MORE THAN

NOISELESS JOYRIDE

TOPIC OF THE DAY

4 5

No.3 10/2018

Transmashholding-upgraded trains account for 46% of Budapest metro’s entire fleet

The M3 line has a full complement of upgraded metro coaches

Some 40 years rewound In 2015 the Budapest metro system issued an invitation to tender to modernize the coaches running on the third line of the Hungarian capital’s tube - the service life of the trains assembled at the My tishchi factor y nearly 40 years back was approaching its end, and the Budapest authorities decided against procuring new coaches, but to extend the service life of the old ones. Tenders were submitted by six companies: France’s Alstom Transport SA, Spain’s Construcciones у Auxiliar de Fer ro c ar r i les S . A . (C AF), C ze chia’s Ško da Transportation a.s., Estonia’s Skinest Rail a.s., as well as by one company each from Rumania and Hungary itself. The contract, however, was awarded to the original manufac turer of the coaches - AO Metrowagonmash.

On 24 March 2017 a ceremony took place in Budapest to inaugurate the first metro train, an 81 -717.2K/714.2K, modernized at Metrowagonmash’s plant near Moscow. The event was attended by Budapest mayor István Tarlós, Metrowagonmash general director Boris Bogatyryov and representatives from the Budapest Transport Privately Held Corporation (BKV, runs the metro system).

All those present had the opportunity to test the upgraded metro coaches on the line.

As at 3 April 2018, the M3 line of the Budapest metro system only operates 81-717.2K/714.2K trains. On 26 May was held a ceremony to send the last, the 37th, metro train to the Hungarian capital. The rolling stock modernization contract between Metrowagonmash and BKV was successfully completed on 12 June of this year.

Better than newThe improved trains are more comfortable and safer for the passengers and engine drivers. The coaches are designed to be used both under and above ground (for above-ground exposure up to 40 minutes).

The upgraded carriages 81-717.2K and 81-714.2K have fibreglass masks with smooth contours of the front portion of head carriages. On the left in the cab is an emergency exit with a folding ladder to evacuate the passengers through the driver’s cab in emergencies. Behind the windscreen are two pairs of LED bumper lights, one of which is embedded in the emergency door.

T h e up gr ad e e x ten ds to th e p ass en g er compartment, the cab and the control panel. The windscreen of the driver’s compartment is made of colourless multi-layered safety glass; the front and side windows have electric heating. The cab has a new console with digital monitors, a comfortable pneumatically sprung seat for the driver, and a folding seat. The crew compartment has an air conditioner and a heat blower. The cab design focused on ergonomic performance and user-friendliness of key controls. The primary controls include a controller with four lever positions for forward, one for neutral and three for brake, control buttons for train systems, a radio transceiver and a pneumatic brake valve. In the instrument cluster are a multi-function display of the IT system and a monitor of the microprocessor-based system for train control, diagnostics and safety.

In the passenger compartment, the upgrade affected almost everything: from wall panels to handrails to lighting. The passenger compartment windows are made of safety glass. Door closure is accompanied by sound and light signals, the train does not start until the doors are closed. The doors have a sensitive edge system, which will reopen the doors automatically if they encounter an obstacle. The compartments have semi-soft benches aligned along the walls of the coach. Two more folding seats have been added (when folded, the space can accommo date a whe ele d c ar r iage [pram/wheelchair]). The lighting uses LED strips, which do not require servicing unlike fluorescent tubes.

SPECIFICATIONS

Parameter 81–717.2К 81–714.2К

Seating capacity 40 42

Train holding capacity at 5 pers./m2 1094

Design speed, kph 90

Average acceleration, m/sec., at least 0,9 1,3

Average deceleration under electric braking, m/sec., at least

0,9 1,3

Coach coupler-to-coupler length, mm, max 19512 19210

Coach width, mm, max 2694

Cab ceiling height, mm 2100

Coach weight (empty), tonnes 34 33

Maximum train axle load, kN 147

TOPIC OF THE DAY

6 7

No.3 10/2018

BORIS BOGATYRYOV, general director of AO Metrowagonmash:

- Over the life of the contract - in less than 3 years - the Metrowagonmash staff completed a great amount of refurbishment and upgrading on 222 metro cars for the M3 line of the Budapest metro system.It involved an overhaul of the interior and the cab, the installation of new electrics, microclimate systems, state-of-the-art control systems, and replacement of the traction drive and brake system. The upgraded coaches had been made at our plant and used by the Budapest metro system since the 1970s. The effort extended the service life of the rolling stock by another 25 years.

The wagon bogies are also new, with a redesigned frame. The double-sprung suspension of bogies ensures smooth movement of the train. The train infrastructure has been raised to a whole new level, with the brake, compressor and safety systems replaced.

The asynchronous traction drive, across-the-line start and heat recovery will make it possible to dramatically reduce the heat released by the coach, while saving up to 50% of energy for traction across the entire speed range. The train can have an autopilot installed. The coaches have a CCTV system installed; the doors have a noiseless electric drive. The train has an air conditioning system installed in the driver’s compartment and forced ventilation in the passenger compartment. The coach upgrade significantly improved the reliability of equipment and repairability of the rolling stock and reduced electric power consumption (to 30%) and the noise level in the coaches. Significant gains have been made in the reliability and energy efficiency of trains as well as in the cost-ef fectiveness of their maintenance and repair.

According to Metrowagonmash CEO Boris Bogatyryov, the contract was fulfilled well and on schedule - using cutting-edge solutions.

The upgraded metro trains have been successfully deployed on the Budapest tube. And the residents of the Hungarian capital have been able to fully appreciate their new comfort and safety.

INCIDENTALLYTransmashholding’s aftersales service for upgraded trains. Russian engineers carefully monitor them and advise their Hungarian colleagues as needed.

is the total distance travelled by the entire fleet of coaches over the service

life of 81-717.2K/714.2K metro cars in the Budapest metro system (the mileage by

train averages 44,328 km)

1 640 168 km

of upgraded coaches run in the Budapest metro system every day (once the M3 line

refurbishment is completed, all 37 trains will be deployed)

are carried every day by Transmashholding upgraded coaches

553 000PEOPLE

OPERATIONAL MILESTONES

TRAINS20

JÁNOS BALLA, Hungarian ambassador to Russia:

- This project is very important for Budapest because the Hungarian metro is one of the earliest in Europe and the first one on the continent.The successful upgrading raised the quality of metro services to a new level. I am confident that cooperation between Transmashholding and the Budapest metro system will continue.

TOPIC OF THE DAY

8 9

No.3 10/2018

DENIS SHILO, head of engineering at Transmashholding’s urban transport development directorate and leader of the M3 line train upgrade project:

- The Budapest metro system is rising to a whole new level technologically. The modernization of the trains on the M3 line is part of an overall package programme to improve passenger service and comfort. Along with the introduction of upgraded rolling stock, the Budapest metro is conducting a global infrastructure refurbishment on the M3 line, which is the busiest in Budapest. The M3 cuts through the city and connects it to the airport; that is, it serves as a kind of poster child for the city’s transport system. For Metrowagonmash and Transmashholding in general, this is a large-scale and socially significant project that enabled us to implement cutting-edge innovative solutions, to make a contribution to further development of the transport system of the Hungarian capital.

The locomotive was designed to state-of-the-art standards for green rolling stock and traffic

safety.

2002: Modern TEP70BS diesel locomotive for long-distance passenger service,

120 / 160 kpH

the first TEP70BS diesel locomotive built. Mass production began in 2006.

BACKGROUND

The system of centralized power supply to the train coaches has modular design, adopted by the manufacturer as the basis for a standard line of new locomotives. The TEP70BS diesel locomotives are used for passenger carriage

on the main railway lines in Russia, Lithuania, Belarus and Uzbekistan.

NEW TEP70BS: NO MORE OBSTACLES IN THE WAY The rail circuits of unelectrified railways cannot

conduct the reverse power supply currentsrequired to energize trains of modern coaches.Two years ago, the Russian Railways managementtasked Transmashholding with improving theTEP70BS series diesel locomotive so that it couldpower a train of 20 double-decker coaches. Thenew versions of TEP70BS diesel locomotives weresuccessfully tested last June and are already inoperation.

By force of willIn the summer of 2016, in furtherance of a comprehensive long-term programme to introduce double-decker coaches and with a view to enabling centralized power supply to passenger trains from the powerplant of the TEP70BS series diesel locomotive, the Kolomna manufacturer started work on a locomotive with a two-wire train coach power supply system for use on unelectrified rail sections.

The Kolomna locomotive builders worked out all details of technical requirements with the customer, Russian Railways, and the co-contractor, the Tver wagon manufacturer, which designs and makes the new double-decker coaches. The chief designer of locomotive and power systems at the Kolomna manufacturer decided to make a multi-purpose diesel locomotive, one that could use one- and two-wire power supply schemes, which would make it possible to drive trains on any tracks.

The rail circuits of unelectrified railways cannot conduct the reverse power supply currents required to energize trains of modern coaches. Two years ago, the Russian Railways management tasked Transmashholding with improving the TEP70BS series diesel locomotive so that it could power a train of 20 double-decker coaches. The new versions of TEP70BS diesel locomotives were successfully tested last June and are already in operation.

design speed

2942 kW / 4000 Hp

PREMIERE

10 11

No.3 10/2018

The two TEP70BS diesel locomotives, No 318 and 317, which have full local content, successfully passed certification tests. And in June 2018, the modernized TEP70BS long-distance passenger diesel locomotive was certified for conformance to the Technical Regulation of the Customs Union for a period of 5 years. The improved locomotive does not look much different from the earlier versions of TEPBS diesel locomotives used by Russian Railways, but it supports coupling and has a two-wire system for power supply to train coaches.

No electricity? Not a problem!By the end of August 2018, the Kolomna maker built four modernized TEP70BS locomotives. Another four are expected to be delivered before the year is out.

More powerful togetherTwo modernized TEP70BS diesel locomotives were produced for certification testing because the tests required a t wo -unit system. A single locomotive is unable to pull a train of 20 double-decker coaches, which also need to be powered, at the specified speed. The power supply system of a TEP70BS diesel locomotive outputs 600 kW, but 20 coaches need 1200 kW. This requires two locomotives to work in tandem. The control systems of the diesel locomotives are coupled u s i n g l o c o m o t i v e i n t e r f a c e s , a n d t h e microprocessor-based control systems via communication interfaces, with a master-slave control implemented at the lead locomotive. If necessary, the diesel locomotives can be decoupled and used separately.

MIKHAIL LUSHNIKOV, engine driver, Ivanovo depot, North Railway Line. 40+ years seniority:

- Over the years of my employment, I drove virtually all locomotives that were made by the Kolomna manufacturer (and by others): TEZ, 2TE10L, TEP60, TEP70... And I have something to compare the modernized TEP70BSs. I’m very happy with this diesel locomotive. I like its SCU (screw compressor unit): it doesn’t make as much noise and makes the air brake system more responsive; about the electronics: I like it that the monitors show all malfunctions. The locomotive does a good turn of speed. The locomotive runs at a speed of 140 kph.

DESIGN FEATURES OF TEP70BS DIESEL

LOCOMOTIVETrain coach power

supply system

Improved 2A-9DG-01 diesel generator

Microprocessor-based control, monitoring and

diagnostics system

High-performance fan of cooling unit (CU)

New console with improved ergonomic

design and output to a display

Bogie with improved component design

Integrated system of automatic heat media temperature control

Two-stage air cleaner of diesel

Wheel flange lubricator

Air conditioner in driver’s compartment

Integrated safety system KLUB-U

Shock-resistant front and side windows with

electric heating

Electrical pantograph wipers

Two locomotives successfully deployed on North Railway. One diesel locomotive is sent to the Dno motive power depot on the Oktyabrskaya [October] railway line, where it is to be deployed on the unelectrified section Dno - St Petersburg.

Russia has quite a few of such unelectrified sections where there is demand for modernized TEP70BS diesel locomotives. The Administration of the Kolomna manufacturer has already received requests to re-engineer locomotives used by different depots for two-wire power supply. But this is a very labour-intensive and challenging task , which Involves making i m p r o v e m e n t s t o t h e d e s i g n o f e a r l i e r locomotives. That is why the manufacturer will be making modernized TEP70BSs, which makes sense to the manufacturer and its customers alike.

ANDREY AKSENYUK, deputy chief designer of locomotive and power systems, Meritorious Industrial Worker of Moscow Oblast:

- The task was a challenge because it involved installing additional equipment on a mass-produced locomotive: power connectors for the minus circuit of power supply, and umbilical connectors for the integration of the control circuits of two diesel locomotives; improving the microprocessor-based control systems, hardware and software; setting up an interface connection between the microprocessor-based control systems...OAO Electrovypryamitel made an improved rectifying unit to our specifications, with an added power supply terminal of the minus circuit, more power terminals and safety devices. All of the above had to be fitted in without a major redesign of the diesel locomotive. All of our designers made a contribution to the end result, each within his area of expertise.

Inspection at the engine-room of a 2A-9DG-01 diesel generator after bench testing

PREMIERE

12 13

No.3 10/2018

No.3 10/2018

To sit back and relax with a cup of fragrant coffee, a magazine or watch a favourite film without a care in the world; in this day and age, you can do all of the above not only in the comfort of your home, but also while commuting. And those who use rail services can now also combine travel with sightseeing. It has been a little over two months since a train started running between Tyumen and Tobolsk, styled after tourism projects such as Imperial Route and VisitTyumen. The comfortable coaches for it are made by the Tver wagon manufacturer.

Innovative family Mass production of interstate chair cars model 61-4458 was started by the Tver wagon manufacturer in 2009. The model was given a new rustproof body with flat corrugated panelling on the outer side walls and flat panelling on the bottom walls. The coaches have state-of-the-art life support systems that ensure

comfort and safety of passengers. All seats in the coaches have foldable tables, armrests and footrests. The interior ended up resembling an aircraft cabin. That is why conductors started talking about plane-like coaches.

- The design of model 61-4458 was ahead of its time, says Sergey Platonov, head of the

OPERATION

14 15

PLANE-LIKE

COACHES

No.3 10/2018

Catering to tourists Apart from their design features, comfort in the new coaches is also provided through better service by the operating company. Specifically, Sverdlovsk Commuter Service Company offers passengers free guides for Tobolsk and Tyumen Oblast and invites them to take an audio tour and learn about the history of the stations and population centres on the route as well as about the life of Emperor Nicholas II and his family.

- The Imperial Route is a new tourism project on the map of Russia, says Andrey Panteleyev, head of the Consumer Market and Tourism Department of Tyumen Oblast. - In all, it will integrate ten provinces. And the new train service connects two destinations on the route: Tyumen, from where the last royal family left for exile, and Tobolsk, where they lived for nine months before their tragic end.

The Imperial Route tourism project branding has been applied to four of the coaches delivered for operation. Also two coaches are styled after the VisitTyumen project, which is the face of Tyumen Oblast. The passengers in that section of the train are in a position to learn about the history of Siberia and its landmarks.

Sverdlovsk Commuter Service Company acquired the rolling stock made by the Tver wagon manufacturer under a finance lease with support from the government of Tyumen Oblast.

onboard electrics design department at OOO TMH Engineering. - The new coach had two variants: first and second class. The first-class coach had an LCD TV installed in the back of each seat; in the second class, the TVs were on the ceiling of the compartment. The onboard video service was the first one for this type of coach. This coach joined the new product line, which started rolling off the TVZ production line at the end of the noughties: second- (61-4440) and third-class (61-4447) sleeper and train manager’s (61-4445) carriages.

In 2013, however, when demand for interstate chair cars slumped, their manufacture was halted. But not for long as it turned out. Four years later, there was a resurgence of demand. The manufacturer received an order to make eight interstate coaches from Sverdlovskaya Prigorodnaia Kompaniya [Sverdlovsk Commuter Service Company]. A supply contract was signed in January 2018. And as soon as May, TVZ obtained a certificate of conformity for the products after successful certification testing. The coach was a good addition to the modern family of passenger rolling stock made by the Tver wagon manufacturer today. The original design was modified as requested by the customer.

The bodies are made of corrosion-resistant steels, rated for 40 years. The standard layout of coaches (modification 61-4458.00) provides for the installation of 60 ergonomic seats with a tiltable back, the first-class coach (modification 61-4458.01) for 40 seats with a tiltable back and a 180-degree rotation. Apart from the former amenities such as armrests, foldable tables and footrests, each block of seats has embedded personal audio modules and sockets. The coaches have air-conditioning systems, polling systems, CCTV, WiFi, information displays, water coolers, showcases and eco-friendly WC units. The compartments have monitors, tilted at the best viewing angle, to broadcast educational programming, films and other useful information. In a word, they have everything that inquisitive tourists may need for their travels.

Note that the vehicles commissioned by Sverdlovskaya Prigorodnaia Kompaniya (SPC), addresses at the same time two tasks that the RF Government and President assign the states, i.e., the development of domestic tourism and renewal of rolling stock.

Last summer, the customer received six out of eight coaches, and on 6 July Tyumen witnessed a resentation of the new train.

The second- and first-class coaches have 60 and 40 ergonomic seats respectively The seats have armrests, foldable tables and footrests

The passengers on the tourist train are offered guides for Tobolsk and Tyumen Oblast

OPERATION

16 17

SERGEY PLATONOV, head of the onboard electrics design department, OOO TMH Engineering:

- The design of model 61-4458 was a step ahead of its time. The new coach had two variants: first and second class. In the original design, the first-class coach had an LCD TV installed in the back of each seat; in the second class, the TVs were on the ceiling of the compartment. The onboard video service was the first one for this type of coach. This coach joined the new product line, which started rolling off the TVZ production line at the end of the noughties: second- (61-4440) and third-class (61-4447) sleeper and train manager’s (61-4445) carriages.

No.3 10/2018

but its design also used solutions developed for the train manager’s compartment coach (mod. 61-4445), which was the first to introduce a disabled passenger area.

Apart from compartments, it has a disabled toilet room and a wider lobby.

Note that this is TVZ’s first experiment in branded tourist coaches. And all things considered, it looks like a success. SCSC CEO Yevgeny Savostin said that the eight coaches ordered from TVZ are not the last. According to him, a financeability study is being done on six more such vehicles for acquisition in 2019.

- The company will then be able to deploy two full-scale branded trains with interchangeable coaches, says Yevgeny Savostin.

The unusual commuter train Tyumen - Tobolsk has already gained popularity.

- Since the launch of the upgraded train under the brand of Imperial Route, it has carried more than 20 thousand people, the SCSC press service reports. - A convenient timetable for commuting (to Tobolsk in the morning and back in the evening), additional services such as tea, coffee and, last but not least, comfortable coaches with ergonomic seats; these are the train’s main advantages mentioned by passengers.

This year the interstate railway coach model 61-4458 intends to make the top hundred

- In compliance with instructions from the RF President, Tyumen Oblast is the first state in the Russian Federation to have upgraded its commuter rolling stock, said Yevgeny Savostin, general director of Sverdlovsk Commuter Service Company, during the presentation. - The coach interior has been custom-designed for the Consumer Market and Tourism Department of Tyumen Oblast with a view to promoting the VisitTyumen national tourism project.

The Tver wagon manufacturer will supply another two interstate coaches to the carrier in December 2018. They are designed to provide comfortable carriage to 45 passengers in each compartment as well as tourists with disabilities, including those in wheelchairs.

- The line of interstate coaches has not seen such vehicles before; it is a novel design aimed at improving public service in this country, says Sergey Platonov. -It is not unlike model 61-4458,

products in Russia. The vehicles have already been endorsed by the judges at the provincial round of the All-Russian Competition of the Russia’s 100 Best Products show. Now we wait for the finals. Note that the entrants and products face a high bar. Specifically, the manufacturing entrants are required to have a quality management system in place, follow good manufacturing practices, make import-substitution products and much more.

- Our products are state of the art and competitive, so we are in no doubt that we will make the grade, said Konstantin Tatarnitsev, head of standardization and quality management systems. - By entering the competition, we show what we have achieved and state that we know how to make innovative vehicles that can hold its own against manufacturers of rolling stock not only in Russia but also in Europe.

TVZ has already made the top hundred products in Russia more than once. In 2014 the judges endorsed all models of double-decker coaches; in 2015, the double-decker chair car and luggage and post wagon; in 2016, the Ivolga electric train; and in 2017, a train manager’s double-decker chair car. The vehicles entered this year are also dead certs.

The SPK [Sverdlovsk Commuter Service Company (SCSC)] staff were taught to operate the new coaches directly by the Tver wagon manufacturer

OPERATION

18 19

TVER WAGON MANUFACTURER TO SUPPLY ANOTHER TWO INTERSTATE COACHES TO CARRIER IN DECEMBER 2018. THEY ARE DESIGNED TO PROVIDE COMFORTABLE CARRIAGE TO 45 PASSENGERS IN EACH COMPARTMENT AS WELL AS TOURISTS WITH DISABILITIES, INCLUDING THOSE IN WHEELCHAIRS.

NO FUTURE WITHOUT DIGITIZATION

Digitization is a process that affects all spheres of human activities without exception. And all the industry at first. The concept of digital manufacturing has a major impact on industrial undertakings, with a much greater role afforded to intangible assets such as methodologies, business processes, competencies etc. For Transmashholding, the stepping stone to digitization was Novocherkassky Elektrovozostroitelny Zavod [Novocherkassk Electric Locomotive Builder] (NEVZ). Igor Malakayev, head of the Digital Factory project at NEVZ, talks about progress to date.

New reality Igor Viktorovich, the world is changing

rapidly. Universal access to the Internet, to large databases, the global penetration of touch devices and wireless broadband are digitizing our society. People and machines will soon be able to use a single digital infrastructure in interfacing with each other. What’s in it for NEVZ?

First, this is an opportunity to husband resources in achieving the business goals by cutting the time to plan the best manufacturing scenario, ensure transparency and control based on real-time data. To achieve the goals at all manufacturing stages, the production must be fully controllable and transparent. All these considerations in our life give rise to a new reality - digital economy, where production must be based on software and solutions rather than on machine tools and equipment. What is more, these must be novel solutions: robotization, 3D modelling and printing, computer vision, industrial Internet of Things, virtual reality, machine learning, digital twins of factories, to name but a few.

Any journey begins with the first step. What was the first digitization step at NEVZ?

NEVZ’s first step in implementing the Industry 4.0 solutions that provide for end-to - end digitization of the company and integration of all physical manufacturing assets into a single cyber-physical system was an equipment monitoring system. The initial stage of system implementation affected 36 units of the factory’s critical equipment. You can already see the benefits of the monitoring system, which allows effective use of equipment status data: underutilized production capacity will be made available to another shop, where it will be fully utilized.

The system schools the operators and increases the availability of machine tools by 5-10% on the

average based on a review of the causes of downtime (lean manufacturing). These are, among others, waiting on parts, crane, changeover. Solutions are on the drawing board to minimize them. Plans provide for increasing overall equipment effectiveness (OEE) up to 0.8-0.85.

INTERVIEW

20 21

No.3 10/2018

Equipment performance directly affects the pace of the manufacturing process. A review of the root causes of this lack of synchronization identified it among the main ones. But in order to reach the root cause of the problem, we had to take a long and hard look at the causes of equipment downtime.

How do you monitor the equipment in practice?

Before, we used educated guesses by foremen or videos at best. In this context, it was considered know-how when we used engine hour counters (for the main drive of a machine tool), but the human factor was omnipresent - any system can be overridden.

installed on the machine tool control consoles and I/O interfaces.

Some of the information such as de-energization of a machine tool, operation under control software, emergency stop is recorded by the software automatically; the human factor is totally absent here. All that the operator has to do is correctly choose the cause of downtime from a list of standardized causes. Ultimately, the performance reports enable managerial decisions aimed at improving manufacturing performance.

T h e c o m p a n y e x p e c t s t o s c a l e u p t h e manufacturing equipment monitoring system to about 300 units by the end of 2018: the rest of the critical equipment, all equipment with computer numerical control (CNC), as well as multi-purpose

EQUIPMENT MONITORING SYSTEM IS CAPABLE OF POLLING EQUIPMENT FOR THE FOLLOWING DATA:

• a diagram of equipment utilization in real time;

• itemization of downtime causes

• using a standard list for subsequent analysis and downtime minimization;

• automated computation of overall equipment efficiency (OEE);

• identify the operator, the part being processed

• and the operation being performed;

• make a comparison between the reference CNC

• and the one running the machine tool;

• conduct monitoring of all energy characteristics of the machine tool for optimal utilization of energy resources;

• record the dynamic parameters of machine tool such as rate of rotation and spindle load, the position of feed adjusters, spindle speed

• and manual movements;

• generate a summary of equipment and employee performance in the form of corporate reports

• and perform the automatic emailing thereof to network users;

• provide network notifications, including,

• without limitation, SMS notification to the help desk of emergency shutdowns of critical equipment, which will make it possible to improve the response time and reduce organizational losses.

Having done a comparison study of monitoring equipment offers on the market, the factory experts and the 2050 company opted for the Russian-made AIS Dispetcher [Operations Controller] system.

The system is designed for computer-aided online in-process monitoring of equipment performance and rating. The purpose of the system to be implemented is to improve the performance of equipment and achieve productivity gains as a result.

T h e e q u i p m e n t s t a t u s a n d e m p l o y e e performance data (how long the machine tools were used, how long downtime was, what the reasons were, who of the operators was on duty at that time etc.) are gathered by a software application by polling the controllers/recorders

INTERVIEW

22 23

No.3 10/2018

KIRILL LIPA, general director, Transmashholding:

- NEVZ is implementing a large pilot project of comprehensive digitization, essentially a digital factory. Everything related to manufacture, solutions, people, movement of material and technical resources and semi-finished products will be entered into a mathematical model on an information system; online communications with a central server will also be in place. This will make it possible to create a unique atmosphere, an IT environment, which we will be able to use to take a fast and deep survey of any process changes.This pilot project will be completed in two years.

Then we will extend it to the other facilities of Transmashholding. We will start as we gain experience and follow up on the decisions being made.

The project can radically change our vision of manufacturing in general. As soon as the factory is digitized, we will have a platform for lightning-fast process improvements.

electric machines. The monitoring system under implementation is a one-size-fits-all solution because it is compatible with all major CNC tools and dumb equipment. The latter is expected to be fitted out with additional sensors to interface with the monitoring system as it does with CNC tools, which have such hardware as part of standard configuration.

Where does all real-time equipment status data end up?

We are already mining large amounts of data from the shop floor, from the infrastructure, with logistics and other enterprise areas, which comes from thousands of sources, as well as being generated by thousands of various sensors. These flows need to be digitized in stages.

The factory has set up a situation centre (SC) to review and process these data in real time. This is a cutting-edge facility, equipped with all means of communication and interactive information presentation.

The expanding scope of digitization across the board at the company keeps increasing the number

parts downtime, NEP, as well as enabling the traceability of assemblies throughout the life cycle and counterfeit control. The pilots also implement a system of intrashop planning with subsequent integration into the existing 1S system.

The specified production sections implement the AIS Dispetcher [Operations Controller] system for equipment performance and status monitoring, which will make it possible to improve equipment utilization, as well as cut the costs of TOiR [maintenance and repair (M&R)]. In the long term it will be possible to conduct equipment troubleshooting remotely, schedule timely repairs based on the actual status and dramatically cut unscheduled downtime of machine tools. We are looking at a wider use of vibration monitoring.

Upon the completion of the pilot projects, the best implemented solutions of Industry 4.0 will be extended to the rest of the factory.

What other digitization applications will be developed at the factory?

The functionality and product digitization plan developed by the OOO 2050 company to implement the project of comprehensive digital transformation of production provides for a number of such applications. First, the industrial Internet of Things (IIoT), to be used for continuous collection and storage of equipment status data (equipment and assembly performance parameters, loads and modes,

processes, operator interventions, errors, condition and statuses, real-time monitoring of overall equipment efficiency), and employee performance data (progress reports, and, which is no small thing, plans are in place to implement functionality to improve health, safety and environment); this also involves transport monitoring, INV tracking and a number of other information flows. Second, artificial intelligence (Al), where simulation modelling will be used to create a digital twin of the factory (a virtual copy of actual production situation). A third application is the integration of information technologies into Internet of Things and creation of a single information space for the systems in place at the company. And finally, the implementation of long-range Industry 4.0 solutions. Implementation is already in progress for a robotic system, a whole section is under design, and a Robotization Roadmap is in the pipeline. Next in line are a smart assembler and computer vision for OTK [quality control department (QCD)], which will drastically cut the [quality] control time, eliminate issues with QCD, as well as contribute to reducing the reject rate and to interactive electronic standard process maps for assembly.

Digitization will improve our competitive capacity and give a fresh impetus to the factory’s growth.

Interview taken Anna SemenyukPhoto by Dmitry Ibraimov

CORE TASKS OF SITUATION CENTRES

Monitoring of target status traffic (equipment, vehicles, inventory movement,

infrastructure etc.) and situation

prediction based on a review of incoming

information using digital simulation model as part of

factory digital twin implementation

Manufacturing situation modelling when implementing various managerial

decisions using a digital simulation model (DSM) for

production

Expert assessment of decisions made

and their optimization

to improve the performance

of industrial processes

Crisis management through prompt

response to contingencies

identified in real time by obtaining

and reviewing data polled from sensors

on monitoring targets

Cascading of real-time data and

analytics to the plant management

level strategic decision making

IT AND IIOT INTEGRATION

INDUSTRY 4.0 SOLUTIONS

• Digital simulation model (DSM)

• 3D model of factory• Post-processing

• Equipment monitoring• INV tracking• Employee monitoring • Quality• Transport logistics

monitoring• Infrastructure

• Vertical integration (PLM, IIoT)

• Horizontal integration (ERP,

• MES, PLC, SCADA)• Additional IT solutions

(web apps)• Completion of Industry

3.0 implementation as part of KTPP [production design and engineering (PD&E)] digitization

• Situation centre• Digital bank of ideas

• Robotization• Computer vision (QCD)• AR/VR (training)• Integral engineering

solutions• Smart assembler

INDUSTRIAL INTERNET OF THINGS (IIOT)

ARTIFICIAL INTELLIGENCE (AI)

FUNCTIONALITY AND PRODUCT DIGITIZATION PLAN of parameters that we monitor through the SC. Ever more at a premium is the response time and prompt decision making, ever stricter requirements are imposed on system interfaces. That is why it is so important that the situation centre enables fast-response communication with similar business units across the group.

Digitization is here to stay T h e i m p l e m e n t a t i o n o f d i g i t a l

m a n u f a c t u r i n g l e a d s t o s i g n i f i c a n t productivity gains and product quality i m p r ove m e n t s, i n o t h e r wo r d s, t o a competitive edge. What are the next steps in this direction?

Digitization pilots are already in place in electric locomotive building shop No 1, electric machine building and blank production and in some sections of the bogie shop. A search is underway for long-range solutions for body production as well.

The shops are already implementing a TMTs [inventory (INV)] inventory tracking system. This will shorten the production cycle by controlling the pace of package supply, employee waiting on

INTERVIEW

24 25

No.3 10/2018