Ufa Motor Plant. History of industry in photographs: PJSC Ufa Engine Production Association
About company
Open Joint-Stock Company"Ufa Engine Production Association" is the largest engine-building enterprise in Russia, founded in 1925. UMPO has been awarded over 30 government awards, including two Orders of Lenin and the Order of the Red Banner, 6 international and 23 Russian awards, consistently occupies high positions in ratings largest enterprises Russia.
Figure-13. Logo of OJSC "Ufa Engine Production Association"
OJSC "UMPO" is located on two production sites in the city of Ufa, Republic of Bashkortostan, and includes 2 specialized production facilities - aviation and tool production, employing about 15 thousand workers, specialists and employees.
The main objective of the enterprise was and remains the production of modern high-quality aviation equipment. During its existence, the company produced more than 50 basic and modified aircraft engines, which were installed on 170 types and modifications of aircraft. More than 25 models and modifications of liquid-propellant rocket engines have been produced for missiles of various classes. More than 100 world aviation records have been set on aircraft powered by Ufa engines. Prime Minister V.V. Putin called the aircraft engines manufactured by the association the absolute pride of Russia. President of the Republic of Belarus Rustem Khamitov, in turn, stated that OJSC UMPO uses the most advanced technologies.
Currently, UMPO produces AL-31F and AL-31FP turbojet engines for Su-27, Su-30 aircraft with all their modifications, R95Sh and R195 for the Su-25 family of aircraft, rotor columns for Ka-27, Ka-28 helicopters , Ka-32, transmissions for Mi-26 helicopters. Since 2010, the association began supplying the Sukhoi Company OJSC plant in Komsomolsk-on-Amur with AL-41F-1S engines (product 117S) for the Su-35S, a 4++ generation fighter that uses fifth-generation technologies.
An important direction - foreign economic activity. JSC "UMPO" for the first time came out with its products on foreign market in 1952. 49 countries around the world use UMPO production equipment; The main trading partner is India, for which the company also produces AL-55I engines installed on HJT-36 training aircraft. The association actively supports foreign partners by organizing licensed production of engines, providing their repair and training specialists from these countries.
JSC UMPO has a full technological cycle for the production of aircraft engines. Mastered technological processes, incl. The unique set of equipment and qualified personnel allow the association to produce the most modern high-tech products.
UMPO provides a full range of services for technical support of its products: after-sales warranty service, repair of modules, components and engines with restoration of all performance characteristics, personnel training, modernization of previously produced equipment.
Along with aviation, the association produces gas turbine engines for ground industrial use. On the basis of AL-31F, the production of the AL-31ST gas turbine drive has been mastered, used as part of gas pumping units with a capacity of 16 MW and AL-31STE for block-modular power plants with a capacity of 20 MW. UMPO can offer potential customers a whole range of products in various configurations, including turnkey delivery of entire stations.
The current quality management system meets the requirements of international standards of the ISO-9001-2001 series, which is confirmed by the certificate of conformity NBP 02.112.0495-2004 in the Military Register voluntary certification system. In 2010, the association received a certificate of compliance of the quality management system with the aerospace standard AS 9100. The AS 9100 certificate increases the competitiveness of JSC UMPO when working with Russian customers and indicates the creation of conditions in the association for the production of high-quality products.
OJSC Ufa Engine-Building Production Association is the largest developer and manufacturer of aircraft engines in Russia. More than 20 thousand people work here. UMPO is part of the United Engine Corporation.
The main activities of the enterprise are the development, production, service and repair of turbojet aircraft engines, the production and repair of helicopter components, and the production of equipment for the oil and gas industry.
UMPO serially produces AL-41F-1S turbojet engines for Su-35S aircraft, AL-31F and AL-31FP engines for the Su-27 and Su-30 families, individual components for Ka and Mi helicopters, AL-gas turbine drives 31ST for gas pumping stations of OJSC Gazprom.
Under the leadership of the association, the development of a promising engine for the fifth generation fighter PAK FA (advanced aviation complex of front-line aviation, T-50) is underway. UMPO participates in cooperation for the production of the PD-14 engine for the newest Russian passenger aircraft MS-21, in the program for the production of VK-2500 helicopter engines, and in the reconfiguration of the production of RD-type engines for MiG aircraft.
1.
Welding in the habitable chamber "Atmosphere-24"
The most interesting stage of engine production is argon arc welding of the most critical components in the habitable chamber, ensuring complete tightness and accuracy of the weld. Especially for UMPO, the Leningrad Institute “Prometheus” in 1981 created one of the largest welding sections in Russia, consisting of two “Atmosphere-24” installations.
2. By sanitary standards a worker can spend no more than 4.5 hours a day in a cell. In the morning there is a check of suits, medical control, and only after that you can start welding.
3. Welders go to Atmosphere-24 in light space suits. They pass through the first doors of the airlock into the chamber, hoses with air are attached to them, the doors are closed and argon is supplied inside the chamber. After it displaces the air, the welders open the second door, enter the chamber and begin to work.
4. Welding of titanium structures begins in the non-oxidizing environment of pure argon.
5. The controlled composition of impurities in argon makes it possible to obtain high-quality welds and increase the fatigue strength of welded structures, providing the possibility of welding in the most hard to reach places through the use of welding torches without the use of a protective nozzle.
6. In full gear, a welder really looks like an astronaut. To obtain permission to work in a habitable chamber, workers undergo a training course; first, they train in full equipment in the air. Usually two weeks is enough to understand whether a person is suitable for such work or not - not everyone can withstand the load.
7. Always in touch with the welders - a specialist monitoring what is happening from the control panel.
8. The operator controls the welding current, monitors the gas analysis system and general condition cameras and worker.
9. No other method of manual welding gives such a result as welding in a habitable chamber. The quality of the seam speaks for itself.
10. Electron beam welding.
Electron beam welding in vacuum is a fully automated process. At UMPO it is carried out using Ebokam installations. Two or three seams are welded at the same time, and with a minimal level of deformation and change in the geometry of the part.
11. One specialist works simultaneously on several electron beam welding installations.
12. Combustion chamber, rotary nozzle and blocks parts nozzle blades require the application of heat-protective coatings using the plasma method. For these purposes, the TSZP-MF-P-1000 robotic complex is used.
13. Tool production
UMPO includes 5 tool shops total number about 2500 people. They are engaged in the manufacture of technological equipment. Here they create machine tools, stamps for hot and cold processing of metals, cutting tool, measuring tools, molds for casting non-ferrous and ferrous alloys.
14. The production of molds for blade casting is carried out on CNC machines.
15. Now it takes only two to three months to create molds, but previously this process took six months or longer.
16. An automated measurement tool detects the smallest deviations from the norm. Parts of a modern engine and tools must be manufactured with extremely precise adherence to all dimensions.
17. Vacuum carburization.
Process automation always involves reducing costs and improving the quality of work performed. This also applies to vacuum carburizing. For cementation - saturating the surface of parts with carbon and increasing their strength - Ipsen vacuum furnaces are used.
18. One worker is enough to service the furnace. The parts undergo chemical-thermal treatment for several hours, after which they become perfectly durable. UMPO specialists have created own program, which allows cementing with increased precision.
19. Foundry
Production in a foundry begins with the production of models. Models for parts are pressed from a special mass different sizes and configurations with subsequent manual finishing.
20. In the area where the lost wax models are made, the workers are predominantly women.
21. Finishing model blocks and obtaining ceramic molds is an important part technological process foundry.
22. Before pouring, ceramic molds are calcined in ovens.
23. The ceramic mold is calcined - then it is ready to be filled with alloy.
24. This is what a ceramic mold filled with an alloy looks like.
25. “Worth its weight in gold” is about a blade with a monocrystalline structure. The technology for producing such a blade is complex, but this part, expensive in all respects, lasts much longer. Each blade is “grown” using a special nickel-tungsten alloy seed.
26. Processing area for a hollow wide-chord fan blade
For the production of hollow wide-chord engine fan blades
PD-14 - the propulsion system of the promising civil aircraft MS-21 -
a special section has been created where cutting and machining of blanks from titanium plates is carried out, final machining of the lock and blade profile, including its mechanical grinding and polishing.
27. Technology has been introduced at the four-axis horizontal machining center final processing the end of the blade blade on a device designed and manufactured at UMPO - the know-how of the enterprise.
28. The complex for the production of turbine and compressor rotors (CPRTK) is the localization of existing capacities for the creation of the main components of a jet drive.
29. Assembling turbine rotors is a labor-intensive process that requires special qualifications of performers. High precision processing of the shaft-disc-toe connection is a guarantee of long-term and reliable operation engine.
30. The multi-stage rotor is assembled into a single whole in the KPTK.
31. Rotor balancing is carried out by representatives of a unique profession, which can only be fully mastered within the factory walls.
32. Production of pipelines and tubes
In order for all engine components to function smoothly - the compressor pumped, the turbine rotated, the nozzle closed or opened - you need to give them commands. " Blood vessels The hearts of the aircraft are considered to be pipelines - it is through them that a wide variety of information is transmitted. UMPO has a workshop that specializes in the manufacture of these “vessels” - pipelines and tubes of various sizes.
33. A mini-factory for the production of pipes requires jewelry handmade- some details are real hand-made works of art.
34.
Many pipe bending operations are also performed by the Bend Master 42 MRV numerical control machine. He bends titanium tubes and of stainless steel. First, the geometry of the pipe is determined using non-contact technology using a standard. The obtained data is sent to a machine that performs preliminary bending, or in factory language - bending. Afterwards, adjustments are made and the final bending of the tube is made.
35. This is what the tubes look like already as part of a finished engine - they entwine it like a spider’s web, and each one performs its task.
36. Final assembly.
In the assembly shop, individual parts and assemblies become a whole engine. Mechanics work here mechanical assembly works of the highest qualifications.
37. Large modules assembled in different areas of the workshop are joined by assemblers into a single whole.
38. The final stage of assembly is the installation of gearboxes with fuel control units, communications and electrical equipment.
39. A mandatory check is carried out for alignment (to eliminate possible vibration) and alignment, since all parts are supplied from different workshops.
40. After presentation tests, the engine is returned to the assembly shop for disassembly, washing and defect detection. First, the product is disassembled and washed with gasoline. Then - external inspection, measurements, special methods control. Some parts and assembly units are sent for the same inspection to manufacturing shops. Then the engine is reassembled for acceptance tests.
41. An assembler assembles a large module.
42. MSR mechanics assemble the greatest creation of engineering of the 20th century - a turbojet engine - manually, strictly checking the technology.
43. The Technical Control Department is responsible for the impeccable quality of all products. Inspectors work in all areas, including the assembly shop.
44. In a separate area, a rotary jet nozzle (RPS) is assembled - important element design that distinguishes the AL-31FP engine from its predecessor AL-31F.
45. The service life of the PRS is 500 hours, and the life of the engine is 1000, so the nozzles need to be made twice as many.
46. The operation of the nozzle and its individual parts is checked on a special mini-stand.
47. An engine equipped with a PRS provides the aircraft with greater maneuverability. The nozzle itself looks quite impressive.
48. The assembly shop has an area where reference samples of engines that have been and are being manufactured for the last 20-25 years are displayed.
49. Engine testing.
Testing an aircraft engine is the final and very important stage in the technological chain. In a specialized workshop, presentation and acceptance tests are carried out on stands equipped with modern automated systems process control.
50. During engine testing, an automated information-measuring system is used, consisting of three computers combined into one local network. Testers monitor engine and test system parameters solely based on computer readings. Test results are processed in real time. All information about the tests performed is stored in a computer database.
51. The assembled engine is tested according to technology. The process can take several days, after which the engine is disassembled, washed, and defective.
52. All information about the tests performed is processed and issued in the form of protocols, graphs, tables, as in in electronic format, and on paper.
54. Appearance testing workshop: once the roar of testing woke up the entire neighborhood, now not a single sound penetrates outside.
55. Workshop No. 40 is the place from where all UMPO products are sent to the customer. But not only - here the final acceptance of products, assemblies, incoming control, preservation, and packaging are carried out.
56. The AL-31F engine is sent for packaging.
57. The engine expects to be carefully wrapped in layers of packing paper and plastic, but that's not all.
58. The engines are placed in special containers designed for them, which are marked depending on the type of product. After packaging comes the accompanying package technical documentation: passports, forms, etc.
59. Engine in action!
I thank the press service of JSC UMPO, in particular, Ekaterina Kosykh for her help in creating the report!
For any questions regarding the use of photographs, please email.
2.1. General characteristics of OJSC "UMPO"
Open joint-stock company "Ufa Engine-Building Production Association" is the largest engine-building enterprise in Russia. The history of the association goes back almost nine decades. Today, JSC UMPO is located at two production sites in the city of Ufa, Republic of Bashkortostan. About 19,000 people work here - workers, specialists and employees.
In 2011, UMPO became the parent enterprise of the “Engines for Combat Aviation” division within the United Engine Corporation (JSC “UK “UEC”). The division was created in order to combine the scientific and production potential of enterprises in the engine-building industry in the development of Russian military aviation. One of the results of the formation of the structure was the emergence of two branches of JSC UMPO in 2012: “Experimental Design Bureau named after A. Lyulka” (Moscow) and “Lytkarinsky Machine-Building Plant” (Lytkarino).
The main activities of OJSC "UMPO":
– development, production, service and repair of turbojet aircraft engines for Su brand fighters and attack aircraft;
– production and repair of helicopter components;
– production and repair of equipment for the gas and energy industries.
The main task of the enterprise is the production of modern high-quality aviation equipment. The entire history of JSC UMPO is connected with the aircraft industry. Over the years of its existence, more than 50 basic and modified aircraft engines have been produced, which were installed on 170 types and modifications of aircraft. More than 25 models and modifications of liquid-propellant rocket engines have been produced for missiles of various classes. A significant amount of work is carried out as part of the execution of government contracts and agreements for the supply of military equipment for the Ministry of Defense of the Russian Federation. Production capacity allows us to produce more than 300 engines per year.
Along with aviation products, the association produces a wide range of products in the field of gas turbine energy and continues to develop new promising aviation products with localization of production on its own premises, as well as aircraft components within the framework of cooperation with Russian and foreign manufacturers.
The association's products are in demand on the world market. JSC UMPO has been exporting equipment since 1952. Today, the association’s partners include enterprises from 8 countries. Issues of international cooperation are given paramount importance. The association actively supports foreign partners by organizing licensed production of engines, providing their repair and training specialists from these countries.
OJSC UMPO has a package of licenses and certificates both for the production and repair of aviation equipment, and for the design and manufacture of gas, energy and oil equipment.
The current quality management system meets the requirements of international standards of the ISO 9001-2008 series.
Thanks to the restructuring of the production process and cost optimization, the introduction of lean manufacturing principles and a developed regional personnel training system, OJSC UMPO has ensured a low level of production costs compared to other enterprises in the industry.
The company has its own anthem, flag, and trademark. The motto of JSC UMPO is: “Reliability and quality – always and in everything.”
In accordance with the Charter, the management bodies of OJSC UMPO are:
General Meeting of Shareholders;
Board of Directors;
CEO.
Structure of management bodies of OJSC UMPO
The General Meeting of Shareholders is the highest management body of the Company. Among other things, the competence of the general meeting includes the election of members of the Board of Directors and the early termination of their powers. Members of the Board of Directors are elected by cumulative voting for the term until the next annual general meeting of shareholders.
External business environment of JSC UMPO:
Competitors:
Volochisk Machine-Building Plant, Ukraine, Volochisk. PA "MTZ";
Smorgon Aggregate Plant, Smorgon, Belarus.
The management of OJSC UMPO does not have a clearly formulated economic security strategy. Since any company in market conditions operates under conditions of uncertainty external environment, then the economic security strategy of OJSC UMPO includes work on checking counterparties (suppliers, consumers and competitors), analyzing proposed transactions, and examining documents. That is, a system of preventive measures is used, which is not enough to ensure effective economic security of a business.