Sespel enterprise. CJSC "Sespel" is a real production on the Chuvash land. Painting of tankers at the Sespel plant

Powerful potential production capacity, amounting to more than 2500 units of the product annually, allows to fully meet the demand of the Russian market. The product range contains more than a hundred modifications and models:

• tanks on automobile chassis;
• tank semi-trailers;
• tank trailers;
• tank containers made of aluminum alloys, stainless steel or low-alloy steel.

The Sespel product range includes feed trucks, flour trucks, cement trucks, grain trucks, fuel trucks, fuel trucks, water trucks, gas carriers, tanks for chemical and food cargo. The volume of the latter is 6.5-89 cubic meters.

The equipment was created using innovative energy-saving technologies that are used in European countries. Thus, the enterprise has plasma, welding, flanging, casting and rolling devices. The plant has all the certificates, meets the requirements of Rostekhnadzor, ISO 9001-2001. Welding works are certified by Germanischer Lloyd Hamburg. The design principle is based on 3D design. At all stages of product development, a certification scheme and end-to-end quality control using electronic document flow data is used.

Historical reference: the enterprise is located in the city of Cheboksary, was founded in 1991 and is engaged in the production of semi-trailers-tanks for the transportation of bulk cargo. Since 2002, the technologies of the companies WABCO, ZINGAMETALL have been actively used in the production of the enterprise.

Specification: production of flour trucks, cement trucks, concrete mixers, tent semitrailers and tanks for the transportation of industrial water.

The lineup: flour trucks of the "Sespel" company are designed for the transportation of bulk cargo, flour, grain, animal feed.

The biaxial dual-slope flour truck 9648 is equipped with a spring suspension, has a tank with a volume of up to 25 m3 and is used with KamAZ-54115, 5460, 6460, 65116 tractors.

One- and two-axle single-sided flour trucks 964804/05/06 with a carrying capacity from 8,700 tons to 21,800 tons are also equipped with a spring suspension, identical to KamAZ, and have a tank with a volume of 13.6 m3 to 33.5 m3.

Three-axle single-sided semi-trailers of the brand 964808/10/11/14 with a carrying capacity from 21 800 tons to 32 000 tons are designed on air suspension, equipped with an anti-tipping function, have a tank with a volume of 33.5 m3 to 55.8 m3 and can be used with KamAZ-6460 tractors , 5460, 65116.

Semi-trailer - concrete mixer 964817 has a tank with a volume of up to 12 m3 and a carrying capacity of up to 28,000 kg, it is used with KamAZ-6460 tractors.

Two-axle, two- or single-sided cement trucks 964801 of the Sespel company are equipped with a tank capacity of 25 m3 and a lifting capacity of 27,000 kg, equipped with leaf spring suspension with a balance bar or air suspension. Cement trucks of the Sespel company with KamAZ-6460 tractors are used.

Semi-trailer tank of brand 964802/03/07, designed for the transportation of bulk cargo, has a tank with a volume of 13.6 m3 to 17.8 m3, can transport from 13,000 kg to 20,000 kg and is used with KamAZ-54115, 5460 tractors, 6460, 65116.

Three-axle single-slope cement tank trucks of the 964809/24 brand, equipped with air suspension, have a lifting capacity from 26,700 kg to 35,000 kg and a tank with a capacity of 25 m3 to 33.5 m3. Such cement trucks with KamAZ-6460 tractors are used.

The 664800 tank semi-trailer with a carrying capacity of up to 12,000 kg, manufactured at the Sespel plant, is intended for the transportation of bulk bulk products, is mounted on a KamAZ chassis and has a tank with a capacity of up to 18.4 m3.

Model 964815, awning and flatbed semitrailers, are used to transport piece goods. The volume of the semitrailer is 98 m3 kg and the carrying capacity reaches 30,000 kg.

A tank trailer 860100 with a tank capacity of up to 10 m3 and a carrying capacity of up to 10,000 kg is intended for the transportation of non-potable water.

Aluminum tanks are also used for the transport of bulk goods. The tank semi-trailer 964818/19/20/21 with a carrying capacity from 22,000 kg to 32,000 kg is equipped with air suspension, it is intended to be used with KamAZ-6460 tractors, and has tanks with a capacity of up to 48 m3.

Modern stage: the level of quality of the products of the Sespel plant is very high, which allows the company to sell its goods everywhere, including selling it on lease.

# 03. Production begins with these sheets of metal, which are stored here on the floor: # 04. Cutting of sheets is carried out both in the old "old-fashioned" way, and with the help of a modern laser installation:
# 05. Again overall plan: to receive sheets, and on the left is a laser cutting machine:
# 06. For feeding metal sheets, the following table is used, with rotating metal rollers:
# 07. Next, the metal sheet goes to the next machine, and here it is rolled into a cylinder:
# 08. You end up with something like this:
# 09. And this is a welding station equipped, attention !!! WiFi module! Welding parameters are set on a remote computer and transmitted via WiFi here:
#10. As promised, the welding process inside the tank:
#eleven. Tank trucks and semi-trailers are equipped with "black boxes", as in airplanes, their main purpose is to record all parameters. And in which case it will save all the important information. Compressed air receiver:
#12. In addition to the cylinder itself, you also need to prepare the bottom. In fact, they are installed not only on the sides, but also inside the tank, as partitions. This is necessary to damp the speed of the transported liquid:
#13. Previously, the bottoms were purchased on the side, but now we have our own machine. A flat round sheet of metal is taken:
#fourteen. And this sheet is attached to the machine, which by rotation (in 20 minutes) will make the necessary workpiece from a flat sheet (it will also process the edges). On the this photo machine with installed blank. The worker greases it with oil and now a flat sheet will be placed on this blank and the rolling process will begin:
#fifteen. It is better to watch the process directly in a short video:#sixteen. There is a similar machine, but for small parts:
# 17. This is how the tank looks like, in which already "extinguishing" partitions are installed:
#18. Automation is very actively used at the plant, bar-coding has been introduced almost everywhere. Barcode Printer for Parts:
#nineteen. There are computers in the workshop, where you can get information about all the details: description, drawings, etc. Employees can come up and quickly find the information they need:
#twenty. Now a new 3D laser welding machine is being installed in the workshop (it has not yet been launched), but the friction stir welding machine is fully operational. To explain, two sheets are installed end-to-end and the device goes and processes this joint (see the video below). In this case, the sheets are upright. and their joint is horizontal (two long yellow strips):
# 21. Machine in action, seam:
# 22. Video: how friction welding works:# 23. It turns out here is such a tank:
#24. General form to the workshop (by the way, the white box is a 3D laser welding machine, which is being mounted so far):
Robotic welding workshop# 25. In a separate room there is a laser and argon welding robot:
# 26. The operator programs it, then leaves the room and waits for the end of the process
# 27. Video. Robot setup:# 28. The necessary details are stored here, note again the barcoding:
How is painting done?# 29. Now our cistern goes into the painting hangar. Here painting is done by hand. 2 women will completely paint her in the desired color in 40 minutes:
#thirty. And this is a new paint hangar. Here, painting is automated and performed by a robot (the robot's hand is now in the far left corner):
# 31. The same robot on the other hand, a computer is installed here (it was not included in the frame) and cans of paint. Unlike two women, who manage painting in 40 minutes, the robot does it in 8 minutes (if not messed up).
Assembly shop.# 32. Some tanks are not painted, but pasted over with ready-made painted plastic sheets (they are purchased from the side):
# 33. After that, the tank goes from one hangar to another (assembly). There is a car wash between the hangars (usual, so there will be no photo). In the assembly hangar there is naturally a large warehouse of all the necessary spare parts:
# 34. A trolley is installed here, each has its own VIN-code, and inside all the necessary parts for assembly. Take and collect:
# 35. VIN code :)

On the occasion of the quarter-century anniversary of the enterprise, we visited the production of tank trucks at the Sespel CJSC plant.
This is one of the most modern, innovative industries in Chuvashia.
The plant, equipped with unique equipment, produces and supplies to many countries of the world semi-trailers, aluminum alloy tanks - cement trucks, flour trucks, fuel trucks, oil trucks, bitumen trucks, lifting tanks, water trucks, feed trucks, tanks for chemical products:

The plant was originally designed following the example of modern European industries. Newest technologies even with a small size and the number of employees, about 500 people can produce more than 2500 tank trucks per year. By the way, 1st place in Chuvashia in the economic competition for 2012 in the category from 300 to 600 people! :)

The company's slogan is "German quality at a Russian price."
Let's see how this is achieved.

First, to make it immediately clear: a modern tanker truck is a very complex design.
Like a regular car, the tanker has an impressive array of passive and active safety features, including anti-lock braking system ABS and road holding system.

In addition, tanks for gasoline and fuel oil, bitumen and grain, flour and cement, chemical products, plain water and compound feed have their own design features:

Vladimir Bakshaev, director of Sespel CJSC, conducted a full tour of the entire production:

The head of the Morgaush district administration, Rostislav Timofeev, was also present.
Such a plant is unique in this agricultural region of the republic. However, they say that in a number of technologies it is also unique in Russia :)

Bloggers listen kipek , cterra , baryshov , makalval and yuriy21 .

Production starts with cutting sheet materials:

And here is the laser itself:

Welding in the workshop is everywhere, in all possible ways:

Laser welded here:

A new 3d laser welding machine is also being installed:

A universal robot for laser or argon welding of bulk parts (the setup process is shown below in the video):

And here is the welding station - though not a robot, but equipped with Wi-Fi (all welding parameters are set on the central computer):

In general, most of the operations here are automated, and all programs are downloaded to machines and robots via Wi-Fi. Accordingly, it does not cost anything to quickly change devices to another part and even material!

For tank bodies, steel, stainless steel and aluminum are used.
Why aluminum is probably not necessary to explain: for transport, weight is always very important.
But it is known to cook light metal most difficult: it instantly oxidizes.
Therefore, argon welding was used earlier (so that without oxygen). This is the quality of the seam obtained after argon welding:

But here's a completely different quality:

This is a friction stir weld seam.
Here, the carbide rod rotates, pressing with effort between the ends of the sheets to be welded. The aluminum melts and neatly fills the seam, which is smooth, without excess metal, and as strong as the sheet itself.
In addition, the heating of the metal is significantly lower and therefore there is no deformation.

The operation of the welding machine is shown below in the video.

Sespel in Russia is a pioneer in the use of this welding technology.
The Faculty of Chemistry of the Chechen State University is involved in mastering the technology and developing its own tools for it.

In general, the "localization" of production is systematically carried out, that is, the independent (and therefore cheaper) production of the largest possible amount of equipment and components.
So, in tank trailers, the expensive German Wabco brake system is used:

Here is a diagram of this complex system:

But part of her insides is already produced here. For example, a receiver that can withstand even more pressure than a German one:

The control panel for the brake system is also "localized":

Plates with Russian inscriptions are engraved here on a laser machine (see also on the video):

But on this machine, the sheet is rolled into a cylinder:

In the design of all tanks, except for the cylindrical body, there are also rounded ends.
Rounding is needed to evenly distribute stresses in the structure (joints with strongly pronounced corners at these corners usually break):

And making such a "cover" is another story! There are not many ways to do this: die casting or stamping.
There is no foundry here; As for stamping, imagine a press for a part with a diameter of 2.5 meters!
Therefore, another interesting technology is used here: rotary drawing, that is, rolling out a round workpiece with a special roller on a matrix:

There are other, smaller, parts that are also made by this method:

How the rotary hood works, see the promised video. Much like a potter shaping a pitcher on a potter's wheel.
Shown is mainly the extraction of a small part; machining a large end piece is less spectacular, although the machine itself is impressive!

By the way, in addition to the usual round ones, the production of oval end elements has also been mastered (in the next photo one can be seen from behind).
Can you guess how this is done? ;)

The internal structure of the tank is not simple. It looks like a shiny barrel from the outside, but inside, even purely by design, there are a lot of details: bulkheads, stiffening ribs, multilayer thermal insulation. For heat-insulated tanks, special designs have been thought out to remove possible cold bridges.
The following photo shows the insulation and the outer protective and decorative coating:

Yes, if thermal insulation is used, then one more detail is required and, accordingly, one more auxiliary production: external end elements.
They, of course, are no longer metal, but plastic:

The technology is similar to the production of acrylic bathtubs:

Reinforcing fibers are poured with a binder and sealed with a vacuum "suction cup":

After assembling the main structural elements, the tank (especially steel) must also be painted.

At first they painted by hand:

And then we got a special painting robot:

The quality of automated painting is the same as that of cars. Moreover, compared to handmade paint is consumed much more economically:

As you have seen, a tanker truck is a multi-axle semi-trailer that attaches to a standard truck.
Accordingly, it has all the necessary automotive parts.
We already talked about a reliable braking system above, now a few words about the suspension.

The assembly of the suspension is also automated, it is carried out according to VIN-codes:

Only high quality components are used, for example, BPW ECO-Plus 2 axles (Germany):

Also installed optional equipment according to the order specification, for example, a "black box" with GPS and GLONASS support.
It allows you to see the entire path and the moment of the accident. We were told a story about how a tanker with a bent nose was sent on a complaint. And the black box showed where and when the driver on the overloaded car could not stand the speed limit and made a blow, hitting the rails at the crossing.
But the benefit of the "black box" is not limited to the analysis of the accident. Since a multi-ton fuel tanker is a particularly dangerous vehicle, it is necessary to carefully select personnel and control the quality of driving. And for this now there is an objective criterion and means of measurement.

And also a compressor is installed on the tankers. The enterprise also develops its own compressor design, which is twice as light as foreign analogues.

Yes, I must also say about the big problems that both producers and consumers face (the avaricious pays twice).

First, there is an abundance of cheap Chinese products, which are made cheaper and easier due to security. A normal manufacturer makes the necessary margin of safety (and this is "extra" weight and price) - and loses the competition.
Therefore, innovative technology is vital for the manufacturer!

Secondly, there is a huge scale of imports of cheap used equipment.
If a manufacturer complies with all strict standards (and they are stricter in Russia than in Europe), and for non-compliance with them, production can be stopped and a license revoked altogether, then no Rostekhnadzor controls imports. Even radiation control is not carried out (and who knows what was transported in imported tanks?).

This is how the domestic manufacturer survives.
The profitability of production rarely exceeds 6%, while the return on equity of the same Sberbank is 20%.
And trading is more profitable than producing. It would be just what to trade!

It's good that we still have industry!

Yes, and we also saw a machine washing floors, which is not superfluous in thin production:

Having looked at all the stages of the production of tank trucks, let's turn our attention to waste.
Aluminum scrap is remelted and shipped for processing to the manufacturer:

Third-party orders can also be carried out - an additional foundry is obtained:

By the way, the crucible for melting aluminum should only be ceramic:

There are other auxiliary industries, for example, gas preparation, treatment facilities, a laboratory where samples are constantly monitored. welding seams; Finally, we have our own design department, the results of which are transmitted using paperless technology directly to machine tools and robotic systems.
We have such a wonderful production, one might say, in the rural outback.

Congratulations to the staff of the enterprise on the 25th anniversary!

Local residents work here, and all the surrounding schoolchildren are sure to go on excursions.
Vladimir Alexandrovich constantly talks about working with young people, about the need to show them factories, industry, real production - and make it profitable and attractive for people, in contrast to the current all-powerful and unproductive trade.
because a person for that and a person to DO something new and useful!

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Dear Sirs,
First of all, let me express my deep respect to you and introduce the company Cheboksary enterprise CJSC "Sespel", a leading Russian manufacturer of tank trucks for almost all types of products. Our company is by far the most high-tech plant in Russia for the production of specialized Vehicle... Possessing new, unique technologies, a multi-stage quality control system, many years of experience and an impeccable reputation. Our company offers a partnership for the production of standard and non-standard tank trucks, as well as other types of special transport equipment, manufactured to the highest standards of European quality level. Factory made tank trucks CJSC "Sespel" adapted to the most severe operating conditions in the Russian Federation.
Engineers pay great attention to every request and carefully develop the technology and parameters of the ordered product in accordance with technical specifications partner. The principle of constant feedback and high professionalism of employees Sespel plant, allows you to always satisfy the most demanding customers in the shortest possible time and at a reasonable cost. Reliable relations with suppliers of components, service technical support allow you to provide maintenance, warranty and post-warranty repair of tank trucks in a short time.
The slogan of our company: "German quality at the Russian price"

Innovative production technologies of the Sespel plant