TURNKEY PROJECTS FOR WHEELS, AXLES AND WHEELSETS MANUFACTURING NOTHING SHOULD STOP YOU

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Sharyl Lynch
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1 TURNKEY PROJECTS FOR WHEELS, AXLES AND WHEELSETS MANUFACTURING NOTHING SHOULD STOP YOU

as turnkey lines. We develop integrated solutions adapted to real customer needs.

2 DANOBAT RAILWAY SOLUTIONS DANOBATGROUP is a leading supplier of global solutions for rolling stock component manufacture and maintenance. Our Railways business unit offers comprehensive solutions for all rolling stock component manufacturing processes: from wheels and axles to bogies and wheelsets, offering stand-alone machines as well as turnkey lines. We develop integrated solutions adapted to real customer needs. With the benefit of our expert knowledge and wide experience in the rail sector we also provide consultancy services to our clients for their real-world issues. Our sensitivity to technological excellence, the high precision of our products and the special care we take to adapt to the real needs of our customers all demonstrate our capability to create cutting-edge solutions. With a high capacity for adaptation, reliability and pro-activity, we accompany our customers in the improvement of their manufacturing processes. Our more than 60 years of experience in the machine tool market and manufacturing systems allows us to offer our customers an enormous added value, with competitive solutions adapted to their specific needs. MANUFACTURING DANOBAT solutions cover everything from wheel and axle manufacturing to wheel assembly from single machines to complete manufacturing lines. DANOBAT RAILWAY SOLUTIONS DEPOT Preventive and corrective maintenance solutions, with a wide range to adapt to the type of vehicle: high speed, locomotive, commuter train, tram or metro. WHEELSHOP DANOBAT is experienced in engineering wheelshops from the ground up. Our expertise covers the whole scope of any wheelshop project: concept, design, execution, commissioning and operation.

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WORLD MAP AND REFERENCES WHEREVER YOU ARE, YOU CAN COUNT ON THE EXPERT

on-time professional service wherever it is needed.

4 WORLD MAP AND REFERENCES WHEREVER YOU ARE, YOU CAN COUNT ON THE EXPERT KNOWLEDGE OF DANOBATGROUP We are close to our customers to provide on-time professional service wherever it is needed. We have an extensive international presence, including our own sales and technical service structure. Our highly qualified locally based professionals and production plants are located at strategic points around the world. WORLDWIDE REFERENCES

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6 OUR RAIL CAPABILITY MATRIX We offer turnkey solutions for highly automated production lines for the manufacture and maintenance of key rolling stock components, such as: wheelsets, axles, wheels and bogies. These production lines are characterised by high productivity, quality and safety. To achieve these objectives, we use cutting-edge machinery, equipment and technology, in line with the Industry 4.0 and Zero Defect Manufacturing paradigms. DESIGN LIFE CYCLE SERVICES PROJECT MANAGEMENT AUTOMATION EXECUTION IDEA OPERATION EQUIPMENT PROCESS COMMISSIONING

7 7 PROCESS Over time, we have developed skills and knowledge that positions us as leaders in turnkey solutions for railway component repair or manufacturing workshops. A profound knowledge of the process, closely linked with customer needs, is one of these key skills. Thanks to current process and production simulation technologies and to virtual factory models, we are capable of anticipating problems and providing collaborative solutions that determine the processes and production flow more effectively. EQUIPMENT We have developed our own key range of machines and equipment aimed at the needs of the rail sector. In addition to our own equipment, we can also take responsibility for defining, incorporating and validating equipment from third parties to offer the best comprehensive solution. AUTOMATION We design and implement automation for the whole production line, including machines, auxiliary equipment, robots, manipulators, etc. as well as the customisation and installation of our own complete monitoring and control software for the total production line with all its elements. PROJECT MANAGEMENT We are very strict in our compliance with deadlines, cost and quality during all stages of the project, through an integral project management focus (PMP certification), with special attention paid to the final acceptance stages, start-up and training for these types of solutions and ensuring an efficient supplier-customer transfer. LIFE CYCLE SERVICES We offer a set of engineering services (TSS, customised maintenance, operational support, process and production simulation), which provide support in the production line operation phase; hence, we cover each of the lifecycle phases of the turnkey solution.

DIGITAL MANUFACTURING The use of Digital Manufacturing tools allows us to make faster, more reliable and smarter decisions in the design and development of turnkey projects for railways depots and

8 DIGITAL MANUFACTURING The use of Digital Manufacturing tools allows us to make faster, more reliable and smarter decisions in the design and development of turnkey projects for railways depots and new railway manufacturing plants. Modelling and virtual capabilities are enhanced with optimisation capabilities, so we can increase the efficiency of multi-stage production facilities for wheels, axles, wheelsets and bogies. PRODUCTION SIMULATION We use production simulation software to configure and optimise material flow, resource utilisation, logistics and flow control for all levels of plant planning. BENEFITS PROCESS SIMULATION We have customised a CAD/CAM system for our wide range of machines aimed at efficient and automatic part program generation. We also provide our machines with a customised post processor. Finally process simulation enables us to perform realistic 3D simulation of entire CNC machines, just like they behave in the shop, with the most accurate collision-detection available. - Calculation of expected throughput. - Calculation of station loads. - Analysis of bottlenecks. - Flow and logic validation. - Buffer sizing. - Resource sizing: machines, handling systems (e.g. automated guided vehicles, portal gantries, robots) and operators. BENEFITS - Definition of cutting parameters. - Cycle calculation. - Tooling and fixturing definition. - Process verification and collision avoidance. - Part programming. - Tool change management.

9 SMART 9 9 FACTORY Smart Factory represents advanced manufacturing systems together with full digital integration to achieve free-flow data sharing in terms of machines connectivity and process control. CONTROL SYSTEM DATA SYSTEM PROCESS CONTROL Tha DANOBAT Data System is a platform for monitoring, visualization, reporting and data analytics of machines in advanced manufacturing systems. - Monitoring: a range of cyber physical devices are customized to capture equipment data. - Visualization: real-time data visualization on any device (PC, tablet or smartphone). - Reporting: customized machine condition reports. - Data Analytics: Big Data analysis for process and machine performance improvement. Earlydetection of potential failures. The DANOBAT Control System provides a central remote operating station for an automated railway wheelshop or manufacturing facility to control, monitor, manage and supervise the progression of the components and equipment through the whole factory. Some of the main features are: - Controls all machines (lathes, grinding machines, boring machines, inspection and measurement equipment, etc.). - Controls all handling systems (e.g. AGVs, portal gantries, robots, etc.). - Controls the production flow and the decision making process. - Monitors status and provides control functions. PROCESS MONITORING - Complete process status dashboard. - Component status management. - Provides supervisory control and data acquisition. - External system integration. - External enterprise system integration (ERP, MES, etc.). - User access control.

10 AUTOMATION

11 SHOP FLOOR AUTOMATION A NEED FOR COMPETITIVE MANUFACTURING Whereas advances in IT and manufacturing technology are widespread, automating the shop floor still holds great potential for improvement

Automation in the railway wheelset maintenance and manufacturing shop is the foundation for a complete shop transformation, resulting in significant benefits in operation repeatability, productivity,

- Cranes. - Turntables. - Automated Guided Vehicles. - Machine sensors. - Cyber Physical Systems.

11 11 SHOP FLOOR AUTOMATION A NEED FOR COMPETITIVE MANUFACTURING Whereas advances in IT and manufacturing technology are widespread, automating the shop floor still holds great potential for improvement in railway wheelset maintenance and manufacturing facilities. Automation in the railway wheelset maintenance and manufacturing shop is the foundation for a complete shop transformation, resulting in significant benefits in operation repeatability, productivity, safety and profitability. An automated railway wheelset maintenance or manufacturing facility utilizes a variety of modern automation systems & technologies, such us: - Robots. - Portal gantries. - Cranes. - Turntables. - Automated Guided Vehicles. - Machine sensors. - Cyber Physical Systems. - Automation systems & technologies move components and assemblies throughout the workshop without human interaction. These automation systems & technologies are fully integrated and controlled by the DANOBAT Control System. We customise all automation systems to meet the wheelshop s current and future production capabilities. We take full responsibility for the design, manufacturing, installation and integration of highly automated railway wheelset maintenance or production facilities.

DANOBAT EQUIPMENT HG/WT GRINDING MACHINE - Ergonomic, rigid and stable design for higher accuracy. - Double wheelhead to work simultaneously and reduce machining cycle time.

- Wheels up to Ø750 x 350 mm or Ø915 x 300 mm driven by 45 kw motor, are assembled on hydrostatic bearing spindles, roller bearing or on DANOBAT designed electrospindles.

12 DANOBAT EQUIPMENT HG/WT GRINDING MACHINE - Ergonomic, rigid and stable design for higher accuracy. - Double wheelhead to work simultaneously and reduce machining cycle time. - Minimum cycle time by diameters, tapers and radius/ faces ground in the same plunge. - DANOBAT gives the best solution according to the type of axle (locomotive, high speed train, wagon...). - Wheels up to Ø750 x 350 mm or Ø915 x 300 mm driven by 45 kw motor, are assembled on hydrostatic bearing spindles, roller bearing or on DANOBAT designed electrospindles. - DANOBAT multi-diameter absolute in process/post process measuring system. TV VERTICAL - Extremely rigid machine structure. - High production output, with a motor power of up to 226 kw - Multitasking machine: rough turning, finishing turning and drilling. - The machine design permits use of different configurations of ATCs: disk type, robot, etc.these systems can be positioned according to customer s layout (backside, left and right). - Fully enclosed machining area allowing machining with high pressure: optimal chip break, longer tool life and temperature control. - Lower maintenance time thanks to the optimized structure of the machine (hydrostatic technology). - Machine designed for optimized chip removal.

13 SM END MACHINING CENTRE - Performs all operation in only one clamping: measuring, milling, journal machining,

- Machine designed for automatic loading and unloading system.

- High stock removal by double headstock. - High dimensional stability and high damping coefficient.

- Can be equipped with part measuring equipment, loading/unloading systems, automatic steady rests, automatic tool

13 13 SM END MACHINING CENTRE - Performs all operation in only one clamping: measuring, milling, journal machining, drilling, centering and tapping. - No penalization for tool change times. - For all types of axles, solid or hollow. - Machine designed for automatic loading and unloading system. DANOBAT EQUIPMENT TCN AXLE TURNING LATHE - Customized for rough or finish operations. - High stock removal by double headstock. - High dimensional stability and high damping coefficient. - Powerful live tools: possibility of performing drilling and tapping in a single machine. - Can be equipped with part measuring equipment, loading/unloading systems, automatic steady rests, automatic tool presetting system, etc. DRM ROLLING MACHINE - Rolling operations for cylindrical and transitional radii surfaces. - Automatic tool changer. - Fast tool change. - GOST compliant. - CNC Controlled rolling forces. - B axis for working angle.

14 CASE STUDY CAF

15 TURNKEY LINE FOR HIGH-SPEED RAIL AXLE MANUFACTURING CASE STUDY 1 OUR SOLUTION - The world s most advanced railway axle manufacturing line, both in terms of the complexity of the

- Automated line for high-speed train axles which ensures the high precision and quality that these components require.

- Simulation and modelling of the complete facility in order to validate the yearly throughput before execution of project.

- Machining: turning, rolling and grinding. - Measurement. - Ultrasonic and magnetic particle inspection. - Robotic system for axle handling.

15 15 TURNKEY LINE FOR HIGH-SPEED RAIL AXLE MANUFACTURING CASE STUDY 1 OUR SOLUTION - The world s most advanced railway axle manufacturing line, both in terms of the complexity of the system, the totally integrated automation, and the variety of innovative solutions on each individual machine. - Automated line for high-speed train axles which ensures the high precision and quality that these components require. - Turnkey line for the manufacturing and verification with high flexibility. - Simulation and modelling of the complete facility in order to validate the yearly throughput before execution of project. (Bottle neck analysis, load analysis, simulation of yearly production mix etc). INSTALLATION CONSISTS OF - Axle identification and automatic loading unit. - Machining: turning, rolling and grinding. - Measurement. - Ultrasonic and magnetic particle inspection. - Robotic system for axle handling. - Modular and customised line control system (traceability, alarm, planning, etc). ADVANTAGES - Optimisation of previous machining processes. - Personalised CAM system for part programing. - All processes are verified offline, guaranteeing 100% machining efficiency. - Increased productivity through reduced set up times. - Quality guaranteed. - Production times are shorter than previous process. - Higher efficiency in human resources usage. - Reduced amount of manual handling operations; higher health and safety conditions. - Less wastage. - Highly repeatable accuracy.

16 CASE STUDY IRCON

17 AUTOMATED WHEELSET MANUFACTURING AND INSPECTION LINE CASE STUDY 2 OUR SOLUTION - Installation of

- Totally new solution. - Centralised control system. ADVANTAGES - High repeatable wheelset quality.

- Integrated project management (idea, design, execution, commissioning, operation assistance and

- Horizontal lathe for axles. - Vertical lathes for wheels. - Grinding machine for axles.

17 17 AUTOMATED WHEELSET MANUFACTURING AND INSPECTION LINE CASE STUDY 2 OUR SOLUTION - Installation of an automated production and assembly line turning out a new wheelset every 18 minutes. - Totally new solution. - Centralised control system. ADVANTAGES - High repeatable wheelset quality. - Minimised operator intervention. - State of the art modernisation. - Integrated project management (idea, design, execution, commissioning, operation assistance and life cycle maintenance). INSTALLATION CONSISTS OF - End machining centre for axles. - Horizontal lathe for axles. - Vertical lathes for wheels. - Grinding machine for axles. - Wheelset measurement equipment. - Wheel press. - Wheelset portal lathe. - Balancing equipment. - Non-Destructive Testing (NDT) system. - Automatic loading and unloading system.

18 CASE STUDY TVSZ

19 AUTOMATED WHEELSET MANUFACTURING AND BOGIE ASSEMBLY LINE CASE STUDY 3 OUR SOLUTION -

- Integrated design including layout, process and work flow.

INSTALLATION CONSISTS OF - End machining centre for axles. - Horizontal lathe for axles.

19 19 AUTOMATED WHEELSET MANUFACTURING AND BOGIE ASSEMBLY LINE CASE STUDY 3 OUR SOLUTION - Automated machining line for 50,000 wheelset per year. - GOST standards. - DANOBAT control system. ADVANTAGES - Wheelset quality optimised through minimal operator intervention. - Integrated design including layout, process and work flow. - Integrated manufacturing and inspection. INSTALLATION CONSISTS OF - End machining centre for axles. - Horizontal lathe for axles. - Vertical lathes for wheels. - Rolling machine for axles. - Grinding machine for axles. - Boring machine for wheels. - Wheelset measurement equipment. - Wheel press. - Bearing press. - Ends cap on station. - Non-Destructive Testing (NDT) system. - Automatic loading and unloading system.

DANOBAT Arriaga kalea 21 E-20870 ELGOIBAR Gipuzkoa Spain T + 34 943 748 044 danobat@danobat.com railways.danobatgroup.

20 DANOBAT Arriaga kalea 21 E ELGOIBAR Gipuzkoa Spain T danobat@danobat.com railways.danobatgroup.com DANOBAT 2016 This document is not contractually binding. DANOBAT reserves the right to make changes to all models without prior notice. The illustrations in this catalogue remain property of DANOBAT. 09/2016

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