Bogies from Graz – your contact with the tracks
Vectron bogies are developed and manufactured in Graz, Austria. Our Graz plant is the world’s leading center for bogie technology and one of the largest development and production facilities for railway bogies. The requisite expertise comes from many years of development and production experience and tradition.
Brief historical overview
The facilities today
Graz is currently one of the world’s largest developers and manufacturers of bogies for metros, trams, trainsets, high-speed trains and locomotives. The plant is capable of producing up to 4,000 bogies per year. This is possible, in part, thanks to the extremely high level of automation in production. The Graz plant is certified to IRIS, ISO 9001, DIN EN 15085-2, ISO 14001 and OHSAS 18001, and is a DB Q1 supplier.
Excerpt from the product portfolio
Development and engineering
The complete development expertise for bogies is concentrated in a single facility in Graz, where the latest simulation methods are used in product development.
The following simulations are performed:
The bogie design is based on a calculation of riding stability, safety against derailment, riding comfort, clearance requirements, and wheel and rail loading.
Strength calculations support the overall development process. Consequently, theoretical and experimental strength verifications are performed throughout.
Production with robotic systems is simulated and optimized early in the construction phase.
Brake simulations determine thermal and geometric brake design.
Early in the construction process, component arrangement and freedom of movement within the bogie in relation to vehicle and clearance are simulated. The simulation is based on 3D CAD modeling for rigid and flexible bodies. Virtual assembly and disassembly procedures are also part of this simulation.
Manufacturing excellence at the Graz plant
The plant covers a total area of 70,000 square meters, with the buildings occupying 46,000 square meters. In 2009, the Graz facility logged approximately 700,000 production hours, with an emphasis on car body construction, mechanical processing, painting, and assembly. Environmental protection is a high priority, attested to by the Environment Prize from the City of Graz and the 2006 Siemens Environment Award. For years, the Graz plant has implemented a comprehensive, continuous improvement process (20 keys).
Car body construction – welding
High productivity and quality: Our highly specialized employees have many years of experience in car body construction. A central element of car body construction is welding. An in-house welding school for training junior staff is located here, with good reason. About 8,000 tons of steel plates and 15,000 km of welding wire are processed in Graz annually. That’s 1,600 km of welds per year – with guaranteed state-of-the-art welding quality. Thus, for example, tandem wire welding robots and combination welding robots (WIG and MAG welding) are also used.
Excellence and expertise: Mechanical production relies on best-in-class machinery. High-quality machine tool technology guarantees optimized machining parameters and maximum cutting speeds. The dry machining process has received a number of environmental awards.
High-tech paint shop
Environmental protection and innovation: Paint jobs are performed in a fully automatic and ecological paint shop that can process solvent-based and water-based paints in parallel.
Over 80% of the paints used are water-based. An important part of painting is waste air purification. The painting process was awarded the Environment Prize of the city of Graz.
Ergonomic and efficient: Assembly is on a module-based series production line with a team workstation structure in which all the workstations are designed in accordance with ergonomic criteria. A paced assembly line has been installed and commissioned for large batches.