KUKA Systems is to supply the complete turnkey welding lines for the construction of the basic elements (side and end walls of the gondolas/hoppers, centre and side sills of the flat cars) for a total of four different wagon types in TVSZ’s Tikhvin plant, which is located about 250 kilometres east of St. Petersburg. Each line measures approximately 160 by 15 metres. Both sides, end walls and flat cars will be produced using gas metal arc and submerged arc welding processes. The highly automated welding cells are not common either in Russia nor in railway vehicle construction, KUKA Systems is setting the industry benchmark. The scope of supply includes 64 robots, 54 KUKA “KS Arctec” technology packages and positioners for parts weighing up to 20 tons. It is intended that some 10,000 wagons a year will be produced with the equipment. The order, which is focused on automated arc welding, also marks further expansion into one of its new market sectors underlining future potential for KUKA.

A KUKA service station to ensure supply with KUKA original spare parts will also be set up on site.

“For us this major contract is a breakthrough of our Industrial Solutions division and further strengthens our diversification strategy”, said Alan Macdonald, managing director of the relevant KUKA Systems division. “We have had excellent business links with the Russian market for many years, traditionally in the automotive sector. This new order allows us to put our expertise into practice in railway vehicle construction and use synergies actively.”

For KUKA Systems being successful in this contract tender means not only growth in a new market but also consistent, sustainable and planned expansion in the BRIC states (Brazil, Russia, India and China). The railway vehicle construction sector is generally accepted as being paramount to future economic growth both in passenger and freight rail transport.