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Since the launch of the workshop, almost 60 electric buses have been assembled on the basis of the Sokolnichesky Car Repair and Construction Plant.

In April, an enterprise of the future was opened on the basis of the Sokolnichesky Carriage Repair and Construction Plant (SVARZ). Now in a workshop built before the revolution, collect buses on electric motors – electric buses. Today it is the most modern electric vehicle plant in Russia. Read the report on how environmentally friendly production works and what the prospects are for this type of transport.

Basis for innovation

Eco-friendly transport is the future, so the capital will gradually replace the entire bus fleet (or most of it), running on diesel, with an electric one. And the logical step was the opening of an assembly plant directly in Moscow. It made it possible to shorten assembly and delivery times and save on logistics and operating costs.

To launch the line, we completely modernized the workshops of the plant with an area of ​​seven thousand square meters. During the renovation process, the roof, windows, floors, lighting, heating, water supply and ventilation systems were replaced. Even in a 30-degree heat in the workshop, a comfortable temperature is easily maintained.

After the modernization, 100 high-tech jobs appeared at the plant. The created production facilities are designed to assemble up to 500 electric buses per year. In order to successfully compete in the market, the plant organized comfortable conditions not only for the assembly of electric buses, but also for the personnel. Showers, dining rooms, office space have been restored, and classrooms and relaxation areas have been created. The approach has fully justified itself – today the plant employs young promising specialists who are interested in their profession.

“Almost 60 electric buses have already been assembled at the innovative plant, and another 200 eco-friendly cars will be assembled by the end of the year, which is more than 60 percent of the total supply of electric buses in 2021. The opening of a plant in Moscow makes it possible to quickly and efficiently develop metropolitan transport, setting a trend for other Russian and foreign cities. Also, production provides the city with new jobs in the field of high technologies, “- said the Deputy Mayor of Moscow, head of the capital

Department of Transport and Road Infrastructure Development Maxim Liksutov.

The main thing is cleanliness

The assembly of the capital’s electric bus begins when the so-called airframe, that is, the body and chassis, is delivered to the plant. The glider is assembled at the NEFAZ plant, a subsidiary of KamAZ PJSC in Bashkiria. And although it is already on wheels, it still cannot drive on its own: there are no instruments, no electrics, no motor elements. Therefore, it is brought to SVARZ on special trawls.

However, the body does not enter the assembly shop immediately, before that it is thoroughly washed. This is not only about the employees’ love for cleanliness: due to the plaque that forms during the delivery process, the bus can subsequently malfunction. And even after cleaning, the blank of the future electric bus first goes to the transfer area to pass the entrance control. Workers check that all components have been delivered and that there are no defects on the case.

Then the machine enters the workshop area. Here it is almost like on the border: close attention to detail and the need to go through several control posts.

“At the first post, traction equipment is assembled, that is, everything that sets the electric bus in motion. These are lithium-ion batteries, switching units, wiring, pantograph, control units, ”explained Marsel Mingaliev, director of electric transport production at PJSC“ NEFAZ ”.

After the first checkpoint, the electric bus travels on its own, but so far it is light – there is nothing inside, not even passenger seats.

They “start” transport just at the second and third posts. Specialists are engaged in the installation of seats, handrails, glass rails, validators, media panels, buttons for alerting the driver, electrical wiring, installation of USB connectors for charging smartphones. In addition, at these stages, side mirrors, headlights, as well as front and rear “masks”, that is, hoods, are installed.

The fourth post is one of the key ones. Diagnostics and calibration of navigation, CCTV cameras and general synchronization of the electronics, for example, adjustment of the position of doors and suspension of the car, take place here. Experts use laptops to connect to the electric bus and, using special programs, test the performance of all electronic systems.

After passing the fourth post, the electric bus is 100 percent ready in terms of assembly. The only thing missing is the upholstery on the seats. In order not to stain the fabric, it is done a little later.

“The Moscow Government has a clear plan to replace diesel buses with environmentally friendly vehicles. The new facility accounts for 40 percent of all assembly operations. These are high-tech and the most expensive operations – from the installation of doors and interior trim to the installation of the “brain” of the electric bus – the central software. A unique feature of the plant is the absence of harmful emissions – the production is completely environmentally friendly, ”said Maxim Liksutov.

Artificial rainfall and urban run-in

After computer diagnostics, electric buses see the light for the first time. They drive into the courtyard to the recharging station in order to continue their journey with renewed vigor and enter the city streets. When fully loaded, the assembled electric bus can roll off the conveyor every 3.5 hours.

“Batteries for an electric bus arrive at the plant from a Moscow supplier with a charge of about 30 percent – this is enough to go through the entire technological assembly chain. After that, 5-10 percent remains, so the electric bus is on ultra-fast charging. It is fully charged in 20 minutes, ”said Marsel Mingaliyev.

So, the projected power reserve of the full battery of the car is 70 kilometers. Taking into account the operation of all systems and the movement of the electric bus in a dense stream with stops, traffic lights are guaranteed to cover 45-50 kilometers.

After fully charged, the electric bus returns to the workshop to the control post, where the brake system is checked and adjusted. At this stage, he can already go to public roads, but is still not ready to receive passengers. According to the technological process, the transport must go through a 40-kilometer run-in. In the field, experts check the assembly of all components of the electric bus and the operation of internal systems. If there are no comments, then the machine goes back to production and starts the test in the sprinkler chamber.

“This special device simulates a powerful downpour from all sides at once: from below, from above, from the side. Since a very serious electronics is installed inside the electric bus, we check not only the tightness of the case, but also the correct location of the contact sections and connectors. Lighting equipment, air conditioners – all devices in the system are tested under extreme conditions, and it is here that all the shortcomings are revealed, ”the expert added.

Sustainable future

After a successful “rainy” test, the electric bus is being prepared for transfer to Mosgortrans. The body is washed and polished, and the salon is completely dry-cleaned. The final touch is the upholstery on the seats.

Then the quality service specialists of Mosgortrans will organize their inspection. They re-run some road tests, such as the emergency braking test.

When the final exam is successfully passed, the electric bus goes to the park, where new cars start their careers in the big city. Thus, the first 10 electric buses assembled at the plant were already on the routes in May – they carry residents of the Beskudnikovo district.

Since the launch of the workshop in Sokolniki, almost 60 electric buses have been assembled. According to the plan, the plant will produce about 200 more cars by the end of the year.

Replacing just one diesel bus with an electric bus reduces carbon dioxide emissions by 60.7 tons per year… The development of the electric bus network has already reduced the amount of emissions into the atmosphere by 40 thousand tons in 2020. And by 2022, the amount of emissions will be halved – 86 thousand tons less annually.

“The electric bus is fully developed in accordance with the technical specifications of the city authorities. It is made exclusively for Moscow and takes into account all the features of a big city. In terms of content, electricity is more environmentally friendly and much cheaper than fuel, ”said the director of electric vehicles production.

He also added that the electric bus is practically silent, it has no emissions, it does not need a network on a permanent basis – an ultra-fast charging station is enough. In addition, due to the design features, the landing is much lower – it is more convenient for passengers.

According to the head of the Moscow Department of Transport and Road Infrastructure Development, the Moscow electric bus is one of the best on the world market in terms of technical and operational characteristics, but at the same time it is 30 percent cheaper than models from other manufacturers, such as Polish and German. Today, more than 650 eco-friendly buses operate in Moscow on 52 city routes.

“During this time, electric buses have proven that they can operate smoothly in any weather conditions: abnormal heat or cold do not affect the quality of the innovative transport. Today, Moscow’s electric bus fleet is the largest among European capitals, and we continue to maintain this level. By 2030, all routes of the city will be served by “green” transport, ”said Maxim Liksutov.

By 2025, all Moscow transport within the Garden Ring will be electric, but Moscow will not stop there. The capital plans to start testing an innovative bus that uses hydrogen as fuel.

EDITOR’S NOTE: This article is a translation. Apologies should the grammar and or sentence structure not be perfect.

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