They withstood the brunt of the disaster at the Sayano-Shushenskaya HPP. They work on submarines and mines. They do not take the tropical humidity and arctic cold. They — the real Tomsk gauges.
Former Tomsk manometer plant, and now — the company "Manotom" managed to secure their devices almost half the world. 70 years of experience combined with the upgraded resource base and stored in the enterprise team can practically work miracles. In the year the plant produced 500 thousand units. Together with all modifications made nomenclature has 10,000 titles. All this comes almost 10 thousand customers from various fields — from shipbuilding to nuclear power plants.
So what is today a manufacturing gauge?
The first step — the development of
It all starts with the fact that the company received the order. The first thing to take the staff of the design department. They determine what should be the instrument. If necessary, order additional engineering equipment, which is made right here in the tool shop. Once the designers create an image of the future instrument, connect to business manufacturing plants.
Develop new modifications made have not so rare — consumers always ask for something new.
Parallel production: from the housing to the spring
From the designers of the development cycle goes to primary production, which employs 700 people, while the fleet of equipment is 527 units. As used herein, technology, by the way, were developed in the factory walls.
Once development introduced in the main production cycle come into play makers buildings. For each type of gauges and pressure sensors need their body. If the device is operated in the not too harsh, the body can be made of plastic or aluminum. If the gauge is made for the military, or will be used in a "harsh" environment — that body is steel.
In different cases, the device enters the body shop or mechanical galvanizing. There is a shop and cold forming.
In parallel with this in other shops is assembling "innards" of the instrument.
The next step — the coloring of the body. Here, too, is not without its know-how. "We have introduced the most advanced technology to date, powder coating, — says the Deputy Director for Operations Andrew Metalnikov. — The bottom line is that the usual coloring of the paint spray atomization method is too expensive. Too much of it simply dissolves in the air without falling on the product. When powder coating paint is used 100%, because that did not get the product, returns to the drum and is not lost. In addition, the coating is more durable and long-lasting. "
A special place in the list of units of the plant — the flexible springs. It is here that make the heart of any gauge. From the quality of the flexible spring depends on the reliability and accuracy of the gauge, its technical characteristics. For "Manotom" Ural-metallurgist experts have developed a special alloy used and produced by the spring.
Plot soldering — the next step. Depending on need or made soft or hard soldering the device, and if necessary, and welding including argon arc.
A separate area — the shop of plastic products. Thanks to modern thermoplastic equipment, there may release details of polypropylene, polystyrene, and any other plastics.
Of course, "Manotom" can not make the production cycle is completely self-contained. For example, glass and metal car parts factory receives from verified suppliers. But, as far as possible, the plant tries everything you need to make in their own workshops. By the way, here work only with Russian materials imported parts are not used.
Those gauges that require strengthening the body, as is almost ready, go to the electroplating shop. His presence — a feature of the Tomsk plant, after all afford to keep electroplating are few businesses. This is a very costly production — and the necessary equipment, and by its very nature. After electroplating — these are different chemicals and acids that must be disposed of after the process. And here is not simply contain a shop, but also to continuously improve workflow in it.
The most important element is the nanometer manufacturing plant that creates gear. The transfer mechanism — is a central element of the pressure gauge, no less important than the spring. The more accurate and thinner running gear, the more accurate readings. Therefore, the production of gears employed the most skilled workers, plant and technical equipment meets the most stringent modern requirements.
"The latest equipment we have installed in mid-2010. It gave several tangible advantages. First, improve the accuracy of machining the gear. It was possible to eliminate roughness, increase the accuracy of our products. Second, because of this we were able to raise the warranty period of our pressure gauges and a half to three years once — twice ", — said Andrey Metalnikov.
Other suppliers of the Russian market gauges still give warranty for one and a half years.
On the assembly line
The final stage of production — assembly line. Major pipelines — four. Each serves its direction: technical instruments, thermometers, special instruments and electric-appliances. This equipment is collected and pass the final quality control.
Before you turn products, each workshop is mandatory checks it for compliance. Quality control department of the plant puts on the product and brand in this process of creating a pressure gauge is completed.
In recent years, "Manotom" developing its service its products. For example, customers of the nearest regions can send a broken item to the factory, where they will be engaged specialists. In more remote areas outside the Russian plant enters into a contract to service their gauges with contractors.
Another new trend in the work — the production of so-called "smart" electronic gauges. Not only do they give out data, but also participate in the management of production facilities, replacing the human operator. So far, their share is not so great — only 15-20%. But the production of such gauges growing all the time.
"Today, our instruments are swimming not only in all the civil, but also on all the military ships, flying in rockets, artillery service. Deliveries are to CIS, Europe, Asia and Africa ", — says Andrey Metalnikov.
Text: Michael Ivaylovsky
Photo: Eugene Shvetsov