Military Review

Kazan Helicopter Plant

14
In October, I, Sergey and Lyosha visited the Kazan Helicopter Plant, which is part of the Russian Helicopters holding, as bloggers who had never been there before. We were shown a mechanical assembly shop, a final assembly shop, some of the plant itself, and even a test flight of the Mi-8.
Но обо всем по порядку.


History Kazan Helicopter Plant originates in 1933, when a wood processing plant was founded on the banks of the Volga in Kazan. And the plant itself calculates its history from September 4, 1940, when the Leningrad aviation Plant number 387, which was later evacuated to Kazan and merged with factory of convoy parts No. 169. The aviation fate of the enterprise was determined in 1940, from this date the history of the current OJSC Kazan Helicopter Plant begins. In 1941, light biplanes became the first aircraft manufactured by the plant.



2. The number of Po-2s released during the war years exceeded 10000 (or more precisely 11334) aircraft, which accounted for 10% of all aircraft released in the Soviet Union during the war years.
In 1951, the serial production of the Mi-1 helicopter, designed by ML Mil, begins. Replaced the Mi-1 came Mi-4.



3. In 1956, the Kazan Helicopter Plant began exporting helicopters.
In 1965, the production of the Mi-8 helicopter began. This was a turning point in the history of the plant. The modern Mi-17 helicopter and its modifications are the result of the vast experience gained during the production and operation of the Mi-8 helicopters.
Kazan Helicopter Production Association in 1993 was transformed into a joint-stock company Kazan Helicopter Plant, and in 1996 it became open - OJSC Kazan Helicopter Plant



4. In the same year, the design bureau was created to develop a light multipurpose Ansat.



Helicopter production:
2006-53
2007-38
2008-58
2009-67
2010-81
2011-94
2012-103
In 2013, an increase of about 10% is expected.



6. Today, the KVZ remains the world's largest manufacturer of middle-class helicopters.



7. The markets traditional for the Russian helicopter industry are: Russia, the CIS countries, the states of Southeast Asia, Africa, Central and South America. Currently, the KVZ supplies equipment to approximately 90 countries of the world (the products of the Russian Helicopters holding company are represented in general in more than 110 countries of the world).



8. This year it is planned to reach a level above 100 machines per year with almost no changes in the composition of the working team - about 7 thousand people with an average age of 36 years (in the shops of mechanical production; in the factory, the average age for today is 43,2 year). And this was achieved through the reorganization of production, which began in the early 2000-s with the repair of workshops.



9. An equally important stage in the reorganization of the enterprise was the purchase of new equipment in the machining industry. We bought foreign-made machines, in this connection labor intensity fell, and labor productivity increased 4 times.



10. Frames are now being processed on four three- and five-axis machines, which replaced the old 24 (three lines of 8 machines each). Russia, unfortunately, has not yet produced machines of this level. In the photo - processed stamping before coating.



11. Ready frames go on the further assembly.



12. The detail for the swashplate for the Ansat was previously made in 18 hours, and now 12. Because of the processing on several machines, the defect was a large percentage. Now the entire turning part, milling, drilling are carried out in one cycle. And so it happens with many details.
In the photo ring ring, which goes to the tail boom on the serial helicopter.



13. The hub of the vibration damper. Not every customer orders it. Previously, the production of this hub took 136 hours, now 18 - the time has decreased by almost eight times!



14. The service of the chief technologist is right there in the workshop behind the glass partition and one does not need to wait for a long time, as before, a specialist until he arrives from another building.



15. The Mazak 2 line operates in the milling shop. One (4 of the machine) processes light alloys (duralumin), the other (3 of the machine) only steel. Each machine has its own shop on 120 tools, and on the “steel” line there is also a shop center on 240 units. Replacing the tool with a “steel” line is automatically generated - this is provided by the software.



16. Suppose the cutter has a resource over, the computer program signals the completion of the assigned resource, the running carriage takes the cutter from the machine, makes the exchange and further details are processed. And the operator takes his mill out. The tool goes to the grinding, its characteristics change and it goes to another production. All tools with chips, which recorded the history of life details.



17. During the restructuring, this shop has increased its capacity more than three times. If you used to make 6 thousands of standard hours, now the plan comes to 21 thousand, and since January 2014 will be even more.



18. Earlier every day a loaded dump truck of duralumin chips left here, now there is more waste in 4 times, but the chips turn into convenient briquettes for transportation, which after melting go to other types of industry.
Every 28 seconds from the press falls duralumin briquette. Every 32 seconds is steel. The cost of briquettes on the market in 4-5 times more than just chips. A tamper cannot make twisted chips in briquettes, so it goes into the meat grinder and after grinding also takes up less space.



19. Ecological protection. There are no rats and mice in the factory. Report Alexey look on his page.



20. Cleanliness - the key to economic growth in production.



21. Moving to the assembly shop.
From the beginning of the assembly to the first flight, the helicopter is here on average one month, including painting production.



22. OJSC Kazan Helicopter Plant, part of the Russian Helicopters holding, produces a family of Mi-8 / 17 helicopters that are operated in more than 100 countries of the world.



23.



24. A wide range of modifications of these helicopters are produced: transport, passenger, rescue, airborne transport, and many others.



25. Since 1997, KVZ has a certificate of helicopter engineering: today, Ansat light twin-engine helicopter is in production.



26. Helicopters of Russia Holding is one of the world leaders in the helicopter industry, the only helicopter developer and manufacturer in Russia, one of the few companies in the world that has the capabilities to design, manufacture, test and maintain modern civilian and military helicopters.



27. As of 2013, Russian Helicopters produced 35% of the world fleet of combat helicopters, 17% of the world fleet of super heavy helicopters with a maximum take-off weight of more than 20 tons, and 56% of the world fleet of medium-weight helicopters with a maximum take-off weight from 8 to 15 tons.



28. The modifications of Mi-8 / 17 helicopters produced in Kazan are a new generation technology.



29. Unique flight performance, the most modern avionics and special equipment produced by Russian and Western companies allow you to fly at high altitudes, in adverse weather conditions, at any time of the day, in automatic mode.



30. Multipurpose helicopter is able to perform a wide range of tasks: transportation of goods, passengers, fire fighting, search and rescue, evacuation of the wounded.



31. For a short period of time, the Mi-8 / 17 can be converted from transport to fire, search and rescue, or sanitary. The options are "salon", "flying hospital" and others.



32. The high level of safety, reliability, simplicity and low cost of operation and maintenance turn the Mi-8 / 17 into one of the best-selling helicopters in its class.



33. The blades are of two types - metal and composite. The composite has a higher resource and less weight, but at the same time it requires more expensive maintenance when replacing or repairing.



34. Black box in the tail boom.



35.



36. Medium transport and passenger helicopter Mi-38.
This new generation helicopter is able to provide a new level of comfort and safety in the performance of passenger traffic and special work in category A (FAR-29). In the basic configuration Mi-38 can carry 30 passengers.



37. Today, the Mi-38 project has entered a new phase.
The third flight prototype is being tested at the flight test base of the Moscow Mil Helicopter Plant OJSC (part of the Russian Helicopters). This prototype is equipped with two TV7-117T turboshaft engines developed by Klimov.



38. The first prototype of the Mi-38 OP-1 made its first flight (hover) on December 22, 2003, and the second prototype of the Mi-38 OP-2, on December 24, 2010. Both of these helicopters were powered by one set of Pratt & Whitney Canada PW127 / 5 turboshaft engines. After removing the PW38 / 1 engines from it, the first Mi-127 OP-5 helicopter was converted in 2011 into a prototype of the Mi-38-2 variant with the installation of TV7-117V engines.



39. JSC "KVZ" began to build the fourth flight prototype. The OP-4 type helicopter will differ from the OP-3 prototype with the shock-resistant Aerazur fuel system and enlarged porthole openings.
In addition to the manufacture of flight prototypes in the 2013 year, in the framework of the R & D on the Mi-38 helicopter, the fuselage and a set of separate units for fatigue tests, as well as components and assemblies for bench tests, are being manufactured. OP-4 - the latest prototype of the helicopter before the start of serial production, scheduled for 2015 year.



40. "Ansat" in the Tatar language means "convenient", "easy."
In 1993, the KVZ created a design bureau whose goal was to develop a helicopter with a maximum take-off weight in 3,3 t, which must meet the aviation requirements of the PAR-29.



41. In February, the KVZ receives a certificate from the IAC Aviation Register, which allows the development of these helicopters. The first flight of the Ansat light multipurpose helicopter was carried out in 1997 by test pilot V.M.Rusetsky.



Aircraft performance

Top speed 275 km / h
Cruising speed 220 km / h
Max. range with main tanks 520 km
Ceiling 5500 m
Static ceiling outside the ground influence zone 3300 m

Mass characteristics
Max. take-off weight 3 300 kg
Max. payload 1 184 kg
GT engines (2хPW207K, Pratt & Whitney)
Power takeoff 630 hp
Power in emergency mode 710 HP

Cabin dimensions
Length 5700 mm
Width 1770 mm
Height 1370 mm
Volume 8,0 m3

Capacity
Flight crew 1-2
7 + 1 passengers



43. Ansat is the only Russian helicopter equipped with a digital electric remote control system (KSU-A). The presence of a digital engine control system allows you to simulate the engine shutdown mode without stopping it.



Transport and passenger modification of the helicopter is designed to perform a wide range of tasks:
- transportation of goods and passengers to remote and inaccessible settlements;
- to use as an air taxi in the city and between settlements;
- delivery of workers' watches to offshore drilling rigs;
- use of a helicopter for corporate transport and general aviation.



45. Ansata's life tests go to the KHP from 1999 onwards.



46. The training modification of the Ansat-U helicopter is intended for training helicopter piloting of cadets of flight schools and civilians, as well as for retraining pilots and improving their skills. Equipping the helicopter with two gas turbine engines in combination with duplication of the main most important units and systems ensures a high level of flight safety in specific flight training conditions.



47. We were not allowed to take pictures of the whole territory, only individual helicopters. Because nobody has canceled secrets.



48. We were lucky - we found the test flight of the Mi-17B-5. The machine flew away for half an hour, then returned.



49. This beauty is made by the KVZ - one of the leading enterprises of the Russian Helicopters holding company, which has stepped over the 70 summer frontier. The company does not cease to increase the pace of production from year to year. Workhorses made in Kazan, a total of more than 50 of millions of flying hours flying around the world, performing a variety of missions in the service of man. The main thing is that the person chooses the tasks more often peaceful - and the helicopters will not let you down!



Thank you for the detailed tour of Valery Alexandrovich Pashko, Director for Marketing and Sales of the Kazan Helicopter Plant, Kalup Igor Igorovich, Galina and Vlade from the Press Service, Head of Mechanical Processing Production.

Author:
Originator:
http://fotografersha.livejournal.com/
14 comments
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  1. saag
    saag 5 December 2013 08: 38 New
    +5
    Are there discount helicopters for your employees?
    1. makarov
      makarov 5 December 2013 08: 52 New
      +3
      On sale "no!", Only for hire - for berries or mushrooms. In a moment of weakness, a collective fishing or hunting flight is provided.
  2. ben gun
    ben gun 5 December 2013 09: 12 New
    +5
    Nice to see such a production! Photographer again and again, THANKS!) good
    1. bairat
      bairat 5 December 2013 09: 46 New
      +4
      The author is touched by a cat on a locker, and I remember what a problem it was. They come from nowhere, a cat can be born in a compartment, a dog can nibble something. We periodically caught them and sent them in returnable containers to our suppliers (well, where else to put them)), after a week other beggars go around the workshop.
  3. La-5
    La-5 5 December 2013 09: 40 New
    +3
    Great photos, thanks to the author.
  4. svp67
    svp67 5 December 2013 10: 07 New
    +5
    Thank! You can talk for a long time and beautifully, so that no one will understand anything, but you can just show the numbers
    2006-53
    2007-38
    2008-58
    2009-67
    2010-81
    2011-94
    2012-103

    And a photo from life, that much would become clear ...
  5. predator.3
    predator.3 5 December 2013 10: 26 New
    +3
    Beautiful photos, order and cleanliness everywhere, and most importantly everyone is smiling good !
  6. ramin_serg
    ramin_serg 5 December 2013 10: 59 New
    +2
    Smiling and plowing

    Respect article

    Factory Workers Great Success

    By the way, when is our order finished?
  7. Sirs
    Sirs 5 December 2013 12: 09 New
    +2
    Ulan-Ude begins to make the MI-17A2 the best helicopter for the army.
  8. pensioner
    pensioner 5 December 2013 16: 13 New
    0
    Thank ! Pleased very much! love
  9. Prapor-527
    Prapor-527 5 December 2013 17: 14 New
    +1
    I love everything related to helicopters (domestic and not only) But our helicopters always stand apart in the global helicopter industry - domestic designers manage to create better machines, and sometimes unique ones, at lower costs. Who else can boast so many world records set by helicopters? Thanks to the author for the article! love And to the domestic helicopter industry, and the Kazan Helicopter Plant in particular, - prosperity, talented young specialists, and more new, wonderful rotorcraft !!!
  10. mithridate
    mithridate 5 December 2013 18: 39 New
    0
    great photo report
  11. samoletil18
    samoletil18 5 December 2013 19: 09 New
    0
    To the author + and thanks. Interesting photos and explanations.
  12. studentmati
    studentmati 5 December 2013 20: 12 New
    0
    This method of transportation of components is still in demand! laughing And sometimes irreplaceable.
  13. zinander
    zinander 5 December 2013 21: 43 New
    0
    My factory didn’t expect that !!!!
  14. Garrym
    Garrym 6 December 2013 01: 03 New
    0
    Great report guys !!!! Well, the plant is generally a sight for sore eyes !!!
  15. twviewer
    twviewer 7 December 2013 03: 52 New
    0
    Beauty, but tell me plz how much has changed in manufacturing technology over the past 20 years? :)