Market Segment:
Railway Industry
Our partner in this project is one of the market leaders in train manufacturing. Addit is responsible for the development of manufacturing technology and the production of crash modules, whose purpose is to absorb impact energy in a controlled manner during collisions, reduce the consequences of an impact, and minimize the risk of train derailment.
Due to their critical safety function, these products are subject to exceptionally stringent quality and regulatory requirements. The crash modules must comply with the EN 15085 CL1 certification level and successfully pass the STBP Part 2 audit as well as the final acceptance performed by the railway operator. The key challenge was to develop a robust welding technology for aluminum components with significant differences in material thickness and to establish a fully automated manufacturing process ensuring repeatability and full compliance with certification requirements.
Addit became involved in the project even before the quotation stage by carrying out manufacturing trials and welding process qualification. The company developed dedicated tooling, implemented a robotic welding cell integrated with a positioner, and created its own solution enabling real-time communication between the collaborative robot (cobot) and the rotary positioner. Thanks to its expertise in automation, welding technologies, and technical documentation, the project successfully passed the certification audit at the very first attempt.
Scope of the Project:
- analysis of technical, quality, and certification requirements for crash modules
- development and qualification of welding technologies in accordance with EN 15085 CL1, EN ISO 15614-2, and EN ISO 15613
- design and manufacture of dedicated fixtures and tooling to ensure the required product geometry
- implementation of a robotic welding cell integrating the cobot, positioner, and welding power source
- production of components including precision sheet metal fabrication, CNC machining, welding, and surface preparation for painting
- implementation of a qualified wet painting system and surface protection in accordance with customer requirements
- preparation of complete manufacturing and quality documentation, along with support throughout the certification process
- execution of quality inspections and preparation of products for final customer acceptance
- launch of automated serial production of crash modules meeting the safety requirements of the railway industry
