jsc epk volzhsky - epkgroup.ru · 2016. 3. 23. · (upa3, upa 4) creating the ... is accredited in...
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JSC EPK Volzhsky
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JSC EPK Volzhsky
Production of over 500 types of bearings for car industry and agricultural machinery
JSC EPK Saratov
Design and production of over 1000 types of bearings for agricultural machinery, metallurgy, defense, railway and automobile industry
Stepnogorsky Bearing Plant
Production of 12 types of bearings for rolling stock
Moscow
Volzhsky
Stepnogorsk
KAZAHSTAN
SamaraSaratov
Russian Federation
St. Petersburg
Omsk
Irkutsk
Nizhniy Novgorod
Central warehouse
Domodedovo
Aviation Bearing Plant (Samara)
Design and production of over 5,000 types of special purpose bearings for aircraft engines and for machine-building industry
ManufacturingplantLogistic center
Moscow plant
Design and production of over 800 types of industrial and rail bearings
JV EPK-Brenco
Design and production of TBU bearings
Geography of Corporation’s enterprises
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March 25, 1961Start-up of first turn on the plantFirst bearings were delivered to the Stalingrad tractor
factory
1971-1975 Development of bearings and providing of serial production for JSC AVTOVAZ
1974-1975Development of bearings and providing of serial
production for JSC KAMAZ.Development of new bearings for automobile models:
Moskvich, Zaparozhec and others.
1978-1980Development of double-row bearings of closed type for
wheel hubs and delivery to JSC AVTOVAZ
1996 Development of high precision bearing production for machine tool industry
1999Lloyd’s Register Quality Assurance certificate of
conformity to quality requirements (Great Britain) ISO 9001:1994
History of the plant
JSC EPK Volzhsky
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2001 Plant joined to holding company JSC EPK
1980 – 2003
•Development of own machine tool building manufacture(creating a department and a workshop of the production motorization and automation)• Bearing development
- for foreign cars on the secondary market- for railway transport (axle boxes)
• Creating the sector of bearing modular production
2005Delivery of bearings and automobile parts to the
companies Daimler AG, GKN, BPW, SAF, ZF, Schmitz Cargobull and others
2008 Production of the double-raw ball bearing of enclosed type for JSC AVTOVAZ
2011
•Certificates of conformity to quality requirements ISO/TS 16949:2002 and ISO 9001:2008 from company TÜV Rheinland •Delivering bearings for the fuel pumps to Czech company Motorpal
2008 – 2014 Development of capacities for forging production
History of the plant
JSC EPK Volzhsky
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Development strategy
• Expansion of bearing market share for automobileconveyor enterprises with development of newproducts and delivery to the foreign automobile plantsin Russia
• Expansion of European sales markets
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Development strategy
Development of the existing production of taper and cylindrical bearings with diameter Ø30 – Ø200 mm
Increasing of capacities for production of hub double-row ball bearings of type Hub Unit First generation for passenger cars
Сreating the production of units for soil processing machines (UPA 3, UPA 4)
Creating the production of type Hub Unit II generation for the passenger cars
Creating the production of double-row taper bearings of type Hub Unit I and II generation for freight motor transport
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JSC EPK Volzhsky bearings
roller bearings Ball bearings
taper bearings cylindrical bearingsdouble-row
single-row double-row single-row
JSC EPK VolzhskyОАО "ЕПК Волжский"
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JSC EPK Volzhsky Test center makes all types of bearing tests in accordance to GOST 520-2011 requirements
JSC EPK Volzhsky Test Centeris accredited in Russian Federal Accreditation Service. Accreditation certificate ROSS RU. 0001.22 SHP06 for
making the metrological, vibroacoustic, bench, metallographic, and other tests, according to accreditation sphere
Test center
JSC EPK VolzhskyОАО "ЕПК Волжский"
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• antitorque moment measuring
• service life testing
• leakage testing in difficult environment
• testing to determine the optimal axle clearance of the bearing in unit
• geometric test
Bearing testing
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Service life testing
Test conditions :
Fr = 600 kgf (point of load application is displaced from bearing middleon 1,4 mm in direction of the support bearings)
Fа = 170 kgf
К = 285 mm (shoulder of applying the axle load)
Tightening torque for fastening nut of the bearing 280 Nм
Rotation frequency of the inner ring n=350/700 rpm
Test time is 5 mln cycles
Продолжительность испытаний – 20 млн. циклов
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The bearing production technology
Manufacture of preparation ( rings, rollers)
- pressing of blanks, turning- cutting, boring, semi-hot calibration
Heat treatment- Annealing of a blank- Quenching of the bearing rings, rollers
Finishing operations- Grinding- Finishing operations- Super-finishing
Bearing assembly- assembly- washing- packing
OAO “EPK Volzhsky”ОАО "ЕПК Волжский"
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Making a blank from a bar for bearing rings
Through-type aggregate for annealing the blanksof bearing rings A/SP-1200 “Elterma”
Blanking operations
Producing the blanks for the bearing rings on the hot forming line L-324,
JSC EPK Volzhsky
Annealing the ring blanks provide:• hardness reducing for machining
• preparation of microstructure for following heat treatment in order to
achieve more metal homogeneity
• internal stresses relieving
ОАО "ЕПК Волжский"
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Production capacity
Turning processing of rings of bearings on machine tools with CNC
OAO “EPK Volzhsky”
Turning process
ОАО "ЕПК Волжский"
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Production capacityGrinding of the bearing rings
Processing of bearing rings by the
grinding-assembly module allows to exclude other types of bearing rings
Finishing operations are made on the modern grinding equipment
OAO “EPK Volzhsky”"
ОАО "ЕПК Волжский"
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turning
Grinding-Assembling module
Machining the rings
JSC EPK Volzhsky
on the multi-spindle semi-automatic lathes
ОАО "ЕПК Волжский"
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Manufacture of bearing cages Manufacture of the cages
of bearing on presses AIDA, Weingarten, Erfurt
на прессах с применением манипуляторов
Production capacity
Manufacture of cages of bearings on presses with using of manipulators
OAO “EPK Volzhsky”ОАО "ЕПК Волжский"
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Making the roller
JSC EPK Volzhsky
Cold forming from a bar
Grinding
Grinding of end face sphere
Superfinishing
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Providing of traceability and identification
According to requirements ISO/TS 16949 the plant has:
• Documentary procedure 7.5.3-01 “Marking and back traceability” defines the order of providing the identification and traceability of the assembled bearings and its parts
• separation of the work flows and obligatory cleaning the work flow to prevent the mixing the close by size parts
• through accompanying documentation for process flow from metal obtaining to packing and delivering the finished products:
- route sheets- quality performance charts
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For testing there are laboratories equipped by facilities for precision measurements
Measuring instruments
- linear and angular values(length gages, sine bars, optical calipers,
interferometers)
- micro geometric values:roughness, linearity, circular deviation,
waviness deviation (profile meter, profile testing instrument,circular geometry gauge)
JSC EPK VolzhskyОАО "ЕПК Волжский"
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Manual control devices for measuring the linear and angular values
Measuring instruments
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JSC EPK VolzhskyОАО "ЕПК Волжский"
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Bearing testing
Material testing
metallographic research of the ringsand rollers for the compliance to
normative-technical documentationrequirement
• steel chemical composition• grain direction (microstructure)
• heat treatment quality (microstructure)
• hardness and other
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Development and productionthe taper and cylindrical, roller and ball bearings is certified by company TÜV Rheinland in accordance torequirements ISO/TS 16949:2009 and ISO 9001:2008
JSC EPK Volzhsky has declaration of product conformity
to requirements of Technical rulesabout wheeled vehicle safety
Product validation on the market
JSC EPK VolzhskyОАО "ЕПК Волжский"
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ВПЗ
Double-row taper roller bearings
Single-row cylindrical roller bearings
- Front wheel hubsand rear wheel hubs
- Axle- Engine
- Transfer case- Gearbox- Engine
Single-row taper roller bearings
- Steering- Gearbox differential- Axle- Wheel reduction gear
Double-row ball bearings
Partners-consumers
JSC EPK Volzhsky"
- Front wheel hubsand rear wheel hubs
- Front wheel hubsand rear wheel hubs
- Engine- Gearbox
http://upload.wikimedia.org/wikipedia/ru/7/7e/Daimler_AG.svghttp://upload.wikimedia.org/wikipedia/ru/7/7e/Daimler_AG.svg
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Thank you for your attention!
Слайд номер 1Слайд номер 2Слайд номер 3Слайд номер 4Development strategyDevelopment strategyJSC EPK Volzhsky bearingsTest centerBearing testingService life testingThe bearing production technologyBlanking operationsProduction capacityProduction capacityMachining the ringsProduction capacityMaking the rollerProviding of traceability and identificationMeasuring instrumentsMeasuring instrumentsBearing testingProduct validation on the marketСлайд номер 23Слайд номер 24