Production of aircraft Su-30 and Yak-130. Irkutsk Aviation Plant
SU-30 is a double generation 4+ fighter. This aircraft is manufactured at the Irkutsk Aviation Plant (IAZ). During its existence, the company has produced more than 7000 aircraft of 20 types. The geography of supplies of IAZ covers 37 countries of the world. In addition to the Su-30MK (modernized, commercial) and Su-30SM (modernized, serial), the plant produces Yak-130 combat training aircraft, components aviation equipment for the Airbus concern, and also begins production of the MS-21 passenger aircraft.
The SU-30CM is a twin-generation fighter of the 4 + generation, created on the basis of the Su-27.
This is the first production aircraft in the world with super-maneuverability.
The fighter is designed to control group combat operations of fighters in solving tasks of gaining air superiority, supporting combat operations of other aviation branches, covering ground troops and objects, destroying landings in the air, as well as conducting air reconnaissance and destroying ground or surface targets.
Su-30SM adapted to the requirements of the Russian Air Force in terms of radar systems, radio communications and government identification. Here are some of its technical characteristics: practical ceiling - 16 300 m, maximum flight range - 3000 km, maximum speed - 2125 km / h.
The Irkutsk Aviation Plant is one of the most significant aircraft manufacturing centers in Russia and is part of the Irkut Corporation.
In 2014, the Irkutsk Aviation Plant celebrates its 80 anniversary.
Production of one aircraft is a technically difficult process, which is divided into many small stages. Each shop of the Irkutsk Aviation Plant performs its part of the process chain.
On this machine HPE JOMAX in the 18-m workshop make the slip tooling. Thanks to modern equipment, one worker per shift performs the amount of work that a team of four performed a month six years ago.
At the blank stamping production (IWP) IAZ is made up to 70% of the details of the future aircraft.
The slag storage area is located in three workshops: stamping, roll forming, and flat work shop.
The metallurgical industry includes 8 workshops. At present, the foundry of the aircraft factory manufactures about 800 product names, blacksmithing - about 2,5 thousand, non-metal shop - about 20 thousand.
In the shops of metallurgical production, parts of the size from a third of a matchbox to the frame of the lantern of the Su-30 aircraft are made.
At the galvanic site, the surface of the part is being prepared for lumcontrol and anodizing. Up to 95% of parts manufactured at the factory passes through the coating and heat treatment shops.
In the process of luminescent inspection, a special solution is applied to the details of the aircraft, and then a powder identifying those defects that can be seen only in ultraviolet light.
This is one of several types of control parts, which are held at IAZ.
In the 34 department, a set of measurements of the geometrical parameters of the parts is carried out using coordinate measuring machines of ultra-high accuracy. In 2013 alone, more than 17 thousands of parts were measured in the department.
In the workshops of the mechanical assembly production, practically all mechanically machined parts of the aircraft structure and its internal filling are made from various types of blanks obtained from the metallurgical and blank-forming production.
Here they are machined on machine tools - the allowances are trimmed, drillings are performed, grooves are selected, etc.
Milling takes at least 80% of the total machine processing time of typical aircraft parts.
In the shops, SMEs are manufactured, assembled and tested units and assemblies of hydropneumatic fuel systems of the aircraft, control systems. It also manufactures entire units - a refueling bar, an aircraft control post, etc.
The units of the mechanical assembly production were among the first to start using modern high-performance equipment at the plant, to introduce lean-technologies. Of the 100 high-performance machines that are currently working in the factory, 65 are SMEs.
After this, the parts are assembled into knots and left back to the coating workshop and from there to the assembly.
Aggregate assembly production. Su-30MKI and Su-30CM assembly line.
In the units of aggregate-assembly production, the center section, the head and tail parts of the fuselage, wings, keels and other elements of the tail assembly are assembled from individual parts.
Then they dock and the almost finished aircraft is transferred to the final assembly shop.
In addition, the manufacture of pipelines, which comprise the aircraft’s hydraulic systems, fuel and oil supply systems, air conditioning and air supply, traditionally refers to the aggregate-assembly production.
Aircraft assembly shop
Assembling combat training aircraft Yak-130
Shop 42 TSA
"First Flight" Yak-130
Assembling the cockpit lantern in the workshop №4
In connection with the implementation of the MC-21 project, the first three flights of the main building were taken up by a new assembly line. Even in the “smallest” MC-21-200 modification, the wingspan of the new liner will be 35,9 meters.
Leading Russian aircraft designers, in particular, IAZ specialists are developing MS-21 cargo and passenger aircraft for domestic and international airlines. The construction of the first flight pattern was completed in January 2014. By 2018, the plant plans to produce 65 airliners per year.
Shop 7. Final assembly shop
The assembly and testing of the main systems of the aircraft: hydraulics, fuel system, engines, wings, landing gear, onboard electronic equipment and weapons in the workshop are 320 people.
Most of the work is done manually. Often have to work bent over three deaths inside the fuselage.
The total length of the wires in the Yak-130 reaches 30 km, and in the Su-30 - more than 70 km.
Today, the aircraft factory employs 12500 employees, whose average age is 40.
The Yak-130 is the only training aircraft in the world with flight performance similar to that of a modern jet fighter. It enables rapid mastering of piloting skills on Su-30, MiG-29, F-16 and other aircraft.
Workshop of International Cooperation (Airbus)
As part of the international industrial cooperation program, JSC Irkut Corporation in 2004 signed contracts with European companies Airbus SAS and EADS for the supply of components for the А320 family of aircraft.
Today, the Irkutsk Aviation Plant, a branch of OJSC Irkut Corporation, conducts serial production and supply of the following high-tech components: a niche of the front landing gear, a keel beam, a flap guide.
On average, every third aircraft of the A320 family is equipped with components manufactured at the IAP.
Shop 16. Flight test unit
This is the most important stage in the production of the aircraft, it is here that the finished machine receives a passport and a “usable” form.
Before leaving the aircraft factory, each machine passes acceptance tests.
The stages of testing are determined by the specifications for the production and testing of aircraft, which, in turn, are fixed by state standards.
The Su-30 radar sees the enemy depending on conditions at a distance of about 200 km. And can capture up to 10 targets simultaneously.
Su-30CM super-maneuverability is provided by thrust vectoring engines. For the first time, this innovative technology was used on production aircraft of the Russian Air Force.
Run engines in different modes
Maximum afterburner thrust is 2 × 12500 kgf
Having received a "passport", the product becomes an airplane that can be taken by the consignee. When the form is signed, the aircraft is received by a representative of the operating organization and a group of technical personnel. Then they call the pilots, they spend flying. If the pilots give the go-ahead, the buyer takes the plane.
In Russia, the equipment flies away "under its own power". For example, the Yak-130, ordered by the Ministry of Defense, flew in 2013 from the IAP airfield to the base in Borisoglebsk. For shipment to foreign consignees, the aircraft is disassembled, packed and shipped by transport aviation.
The cost of one Su-30 CM is $ 50 million.
For 2013, the plant's revenue amounted to 58 billion rubles. The export volume of only one SU-30MKI fighter jets exceeds 10 billion rubles.
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