Focusing on Europe with the new generation products on the production line, and determining the Middle East and North Africa as alternative markets in the coming period, Tüdemsaş comes to the fore with the modernization studies carried out in its factories and facilities in line with the changing and developing needs of the sector. The most obvious example of this; The use of robot welding technology in Tüdemsaş for the first time in the railway sector. During our factory visit, Tüdemsaş General Manager and Chairman of the Board Yıldıray Koçarslan made very important statements.
Using robot welding technology in bogie manufacturing, Tüdemsaş minimizes the mistakes that may occur in the production line, and manufactures wagons with a team of certified welders. These welders are trained by experts at the Welding Technologies and Training Center at certain periods and are subjected to exams. Wagon body wash and Blasting in TÜDEMSAŞ facility also carries the distinction of being the first plant where cars blasting, use of robots in Turkey. With the architect of this change and development, Tüdemsaş General Manager and Chairman Yıldıray Koçarslan, we talked about new investments in the company and robot technology. sohbet we realized.
Can you tell us about your factory? What products are produced here?
TÜDEMSAŞ was founded in 1939 in Sivas as kul Sivas Cer Atölyesi ı in order to repair the steam locomotives and freight wagons used by TCDD. Our company; Wagon Production Factory, Wagon Repair Factory and Metal Works Manufacturing Factory have various support units that contribute to these. Experienced teams of workers, technicians, technicians and engineers work in these units. In our company, with the maintenance, repair and overhaul of more than one thousand wagons of 340 from its establishment to the date of production, a thousand new freight wagons were produced. Today, the production of freight cars maintenance, repair and overhaul largest industry in Turkey at the point of making the institution. Thanks to our long years of experience, know-how and technical infrastructure, we are capable of producing all kinds of cargo wagons in large quantities. In the same year we can produce 21-3 different types of freight wagons. The factories within our company have all kinds of technological looms required by the sector (Horizontal Machining Centers, CNC Lathes, CNC Wheel Lathes, CNC Shears, CNC Plasma, CNC Press Brakes, Weld Blasting, Wet Wash, Wagon Dyeing and Sandblasting Plant etc.) invests itself continuously.
In what operations do you use the robots in your factory? Can you tell us about your new investments and facilities?
Increasing the quality of production day by day, our company is working to increase the capacity of maintenance and revision. In parallel with the technological developments in the sector, we are transforming the old Casting Factory, which has an area of 2008 bin m10 closed 2 bin m12, which has been liquidated in 2, into a modern and technological factory, where maintenance, repair and revisions of wagons are carried out under ECM Maintenance Management System. Once the conversion is complete, it will have many side facilities (such as wagon washers, wagon sandblasting and painting units) that will be needed for the maintenance and repair of wagons, and the maintenance and repair capacity of our Company will be increased significantly. As a company, we attach special importance to the management systems and certification studies which are visas in national and international markets. We have many quality and management system certificates that are required by the sector, which must be owned by organizations that give importance to qualified workforce and quality. However, we have received the TSI (Mutual Operability Technical Specifications) Certificate for the production of freight wagons, which has recently been implemented in Europe and has become a necessity for our country, for our bogie production and two different types of freight wagons. ECM Maintenance Management System-Maintenance Procurement certification, which is needed for maintenance, repair and revision of freight wagons, continues in our works. We have completed our TSI certification process for Rgns and Sgns platform type wagons. In the coming period, we will complete this process for the Talns-type closed ore wagon and the Zacens-type heated fuel transport wagon, and we will mass-produce these wagons. During this certification process; We modernized our factory sites and quality control laboratories. Our material stock areas were expanded on the one hand and renewed on the other. In our company, as we use robot welding technology in bogie production, we have completed the Robot Wagon Washing and Sandblasting Plant which we established in order to make the wagons coming to maintenance, repair or revision in Wagon Repair Factory. This facility; Sandblasting is also used robots, thanks to increasing technical equipment and accordingly, the work capacity is a first in Turkey. The cargo wagons that came to our company were started to be blasted with the help of robots without human factor. The sandblasting process at the robotic sandblasting plant is carried out by means of the 3 robotic arm, which is fixed to the bearings on the roof of the plant and can be moved across the blasting hall. All wagon types and sandblasting zones (bottom, top and side surfaces and forehead areas) are defined at the beginning of the robot, then the blasting process is done automatically without the need for human factor.
Can you tell us what kind of automation and robotic systems you use and what you need in wagon production and repair?
We use robot technology in manufacturing of bogie and sub-components in our wagon production factory. Wagon Repair In our factory, we also perform Wagon Blasting with the help of robots. We also use different automations when testing the bogie and wagon brake. In addition, we use a large number of CNC machines for sheet metal cutting operations and spare parts manufacturing in our Metal Works and Machining Factory. We are planning to increase our production capacity by making new robot investments in order to produce different bogie types within the scope of Wagon Production Factory depending on our increasing production in the coming period. In addition, our R & D studies are continuing to automate the various stages of wagon manufacturing.
What is the name of the robot brand and integrator company you use?
Robot Welded Bogie Manufacturing System has been delivered to the Wagon Production Factory Boji Branch, ALTINAY Robot Teknolojileri A.Ş. was established by the firm. The aim of using robot technology in Bogie Manufacturing is to increase the welding quality and to bring new technologies to our company. The Bogie Robot System is designed to produce 7.5 Bogies in one shift (8 hours). Boji Robot System consists of three stations. Two stations weld the longitudinal carriage, which are the most important sub-assemblies of the bogie frame, and the other station weld the transverse carriage. Welding of the longitudinal carrier at the first station using Tandem Welding technology, one Fanuc M-710iC type Robot and two 400 amp Lincoln Electric Gas Welding Machines; Welding of the transverse conveyor at the second station using two Fanuc Arcmate 120iC type Robots and two 400 amp Lincoln Electric Gas Welding Machines; The welding of the Bogie Longitudinal Carrier with Ø 1.6 mm wire at the third and last station is done by using two Fanuc M-710iC type Robots and two 600 amp Lincoln Electric Gas Welding Machines. In total, Robot Welded Bogie Manufacturing System has 5 Fanuc brand Robots and 6 Lincoln Electric gas welding machines. All of our robots have six axes. The brand of robots used in the Robotic Wagon Sandblasting Plant is FANUC M-710iC / 50. The firm that won the tender; VIG Makine is the subcontractor that installs the robot, and the R&D Robotic company.
ROBOT IS A STRATEGIC INVESTMENT OF OUR COMPANY
How did you decide to convert the robot need to invest and how long did the decision-making, purchase, and installation process take?
Robot Welded Manufacturing System is a strategic investment of our company. The resources made by the human hand differ from the welder to the welder. Even the sources of the same welder on different days differ due to various psychological reasons. Welding of robots with the aim of minimizing the human factor in the source and the standard of resources has come to the agenda. Wagon types produced by our company are different types every year depending on the orders placed. To be able to apply the robot welding you need to have a standard product. This makes it particularly difficult to use robots at the sources of the railcar chassis. However, in recent years, a large part of the wagons produced in the bojili wagons and the same type (standard) is the same type (standard) because of the application of the robot with the bogie is considered more logical and applicable. As a matter of fact, with the established robot system, a certain standard was obtained and the quality of the welds increased. One important reason for the establishment of the robot system is the responsibility of the public to set an example for the private sector in large and different investments. First of all, in the Sivas market, it is also aimed that the medium-sized industrialists in the Central Anatolia Region should see the robot system and experience the usability of this technology in their own business. For these reasons, CNC machines were purchased in our company and various robotic investments were started in recent years.
What advice do you give to investors who want to invest in robot?
Knowing the high initial investment costs in robotic investments, I would like to say that; I think robotic investments are necessary in order to reduce costs in production, shorten production times, minimize the negative effects of the human factor on production, produce quality products in accordance with international standards, increase the competitiveness of companies by integrating with international markets, and become a world-class brand. Thank you for giving us the opportunity to express ourselves with these thoughts, and I wish you success in your work.
THE CAPACITY OF THE ANNUAL 4 THOUSAND BOXING COMPANY
What advantages have been obtained after the robots?
After this investment, the capacity of our company has been increased to 4000 bogie per year. Before the welding system with robots, the weld seams differ depending on the welder's hand angel, but a certain level of quality could not be achieved. After the robotic welding system, a certain level of quality was achieved in the weld seams.
Short Term Achievements of Robot Welded Welding System:
1) Productivity Improvement
2) Improving Production Quality
3) Continuity of Production
4) Controlling Processes
5) Improving Reliability in Production
6) Improving Safety Conditions in Manufacturing
7) Reduction of Fire and Revision Workmanship
8) Ensuring Working Ergonomics
9) Protection of workers from harmful environments
Long Term Achievements of Robot Welded Welding System:
1) Qualified Staff
2) Switch to Planned Maintenance
3) Fixed Cost
4) Continuity in Production
5) Flexibility in Production
6) Quality Advantage in Marketing
7) Company development at automation level
8) Employee Satisfaction
ROBOTLU WAGON SANDBLASTING PLANT
Sandblasting process on the wagon, welding, etc. is a process that must be applied before such operations. In this way, deformation, welding defects or cracks in the chassis or any main part of a car that has been revised or repaired can be seen very clearly and the chance of healthy intervention increases. Likewise, the paint process to be made into the wagon also provides more healthy and lasting results.
Wagon Repair Robotic sandblasting is used in the repair and repair works of wagons coming to our factory. When working at full capacity, 200 wagons can be sandblasted in 2 wagons with surface area of 24 m6. When the truck is a platform-type wagon with less surface area, this number can be up to 10 per day.
Steel grid is used for sandblasting process. In this way, the environment required for the maximum penetration of the paint on the surface of the wagon is also created.
Disadvantages of Manual Wagon Sandblasting:
- Manual sandblasting is unhealthy and dangerous
- The operator is exposed to noise, dust and physical stress.
- Heavy, restrictive protective clothing and ladders are required.
- Accidents and work-related injuries are likely to occur.
- It can often cause delays in production.
Robotic Wagon Shot Blasting Plant as these disadvantages are eliminated;
- In the ergonomically designed, air-conditioned and soundproof cabin, the operator can control the entire process over the SCADA and observe the faults in the system.
- In robotic sandblasting, the operator can observe the pre-programmed robots from the room.