How to collect trolley

There is in our area, in Engels, a trolleybus plant. Abbreviated TrolZa. This is a plant with a rich history, several times changing its profile. Therefore, first tell a little history of the plant.
The plant was founded in the time of the Russian empire - in 1868, in the village of Raditsa, Bryansk district, Oryol region (later it is the Bryansk region). Then it was Raditsky Locomotive Works. And produced locomotives and other products for the railway.
excursion to the trolleybus plant
In 1919, the plant was incorporated into the Uritsky village and was named the Uritsky Carriage Works. During the Great Patriotic War, he was evacuated from Bryansk to Engels. This is how grief helped our region to get such a large production. After all, the production of Engelsky plant - trolley buses (which have been produced since 1951) is used throughout the country. And now, having survived the 90s, Engel plant remained one of the few operating trolleybus plants in Russia. Their competitors are mainly only the Bashkir plant, as well as the Belarusian Belkommunmash.
It is worth saying that the plant is now located exactly at the same place where it was placed after evacuation from Bryansk. The territory of the plant is huge, but now a small part of the territory is used for the needs of the plant. Now almost all production is concentrated in just a few shops. Just in the 90s changed the specifics of production. Now there is no complete cycle of assembling a trolley bus, many components are brought to the factory ready. And the plant has become more automated. Accordingly, the number of employees has decreased. Now the plant employs about 950 people who are capable of assembling 800 trolley buses per year.
excursion to the trolleybus plant
The first model of trolleybuses produced at the plant was MTB-82 (a total of 360 such trolleybuses were released). And then, from 1959 to 1972, they began to produce ZiU-5 - the dominant model of trolleybuses in those years. They could be found not only in the USSR, but also in Poland, Greece, Hungary, Bulgaria, Yugoslavia, Colombia, Argentina, Mongolia.
excursion to the trolleybus plant
In the 1970s, the ZiU-9 model replaced, which became even more popular.
excursion to the trolleybus plant
Oleg Y. Strelnikov - director of production, who conducted a tour for us.A true professional who knows everything about production.
excursion to the trolleybus plant
Now the plant produces trolleybuses of two families: "Optima" and "Megapolis". And more specifically - semi-low-floor (front doors - low-floor, rear - middle-floor) TrolZa-5275 Optima and low-floor TrolZa-5265 Megapolis.
Basically, “Megapolises” are being collected now, since they are in great demand due to the low floor. Such trolley buses are easier for boarding and disembarking passengers. They also have an elongated body (12.5 meters instead of 10 for the Optima). Also, “Megapolises” can bend down due to pneumatic systems, which should facilitate the boarding of passengers, especially disabled people.
Trolleybus assembly begins with the assembly of the frame, the main elements of which (side, roof, frame) are metal. The frame is sheathed and such a model comes in for painting.
excursion to the trolleybus plant
And here we are in the assembly shop, where most of the work takes place.
excursion to the trolleybus plant
Samao first here is the installation of special bridges that allow the trolley bus to be low-floor. These bridges are one of the few overseas components. Bring them from Germany. And so percent for 75 components of the trolleybus of the Russian production.
In the "megacities" put special bridges that have to be imported from abroad. These bridges are designed to allow trolleybuses to have a low landing.
But at “Optim” bridges are standard, which leads to the elevation of the rear part of the trolleybus.
After the frame was assembled, it was painted, bridges were installed - they begin to install electrics and glass. With a large Saratovsteklo plant in Saratov, one would have thought that Saratov glass was used at Trolz. But no: our factory refused the idea of ​​producing such glass. Therefore, glass is brought from Nizhny Novgorod
excursion to the trolleybus plant
In the photo above - ordinary bridges for "Optima". Photo bottom - bridges already for "Megapolis". They differ even in appearance. And it should be said that at the assembly stage, trolleybuses move around the workshop on a special roller belt (something like a tram line) - it turns out a sort of trolleybus conveyor. But it happens that trolleybuses are transferred and by such a crane
excursion to the trolleybus plant
Tires
excursion to the trolleybus plant
For insulation using polyurethane foam, which improves tightness, heat and sound insulation.
In general, at the request of the customer in the complete set of trolley buses, you can make changes.But the chassis at the base model is dual-axle with rear wheel drive
excursion to the trolleybus plant
excursion to the trolleybus plant
Let's go for a short time away from the main shop and look at the plant crimping and preparation of harnesses, which is located nearby. The harnesses are crimped to increase electrical safety.
excursion to the trolleybus plant
And this is what a 180 kW traction electric motor looks like, which is, of course, placed in the back of the trolleybus.
excursion to the trolleybus plant
We all know that trolleybuses use electricity from a contact network for movement. But "Megapolis" stands out here: they have special lithium-ion batteries mounted in the back of the trolley. These batteries allow trolleybuses to travel 25 kilometers in autonomous mode.
excursion to the trolleybus plant
Now they are trying to develop an eco bus that would travel 250 kilometers without recharging.
The next stage of assembly is the installation of roof equipment.
excursion to the trolleybus plant
Where in particular is installed the heating system supplied by the Saratov firm Etna.
excursion to the trolleybus plant
And finally - trim, which uses a special plastic with high fire safety.
excursion to the trolleybus plant
The entire interior of the cabin is supplied by Nizhny Novgorod firms.
excursion to the trolleybus plant
Conveyor assembly line
excursion to the trolleybus plant
Depending on the configuration in the trolley bus, there can be from 28 to 45 (these are already triaxial, rare trolley buses) seats.
The assembled model “moves” to another workshop - for run-in, revision and change.
excursion to the trolleybus plant
Let's take a look at the ready-made trolleybus salon.
Salon "Megapolis"
excursion to the trolleybus plant
Salon "Optima"
excursion to the trolleybus plant
View of the driver's cabin.
excursion to the trolleybus plant
Let's look inside the cabin and see just such a dashboard. Now more and more digital control is being introduced.
excursion to the trolleybus plant
View of the production from above. Green trolley buses are Optima. Blue and white - "Megacities"
excursion to the trolleybus plant
"Megapolises"
excursion to the trolleybus plant
On each model of "Megapolis" you can see the sign "Invalid". This is no accident - these are the models that are best suited for transporting people with disabilities. Well, special bridges allow these trolley buses to also tilt the frame to the sidewalk.
excursion to the trolleybus plant
Top view on the already fully assembled trolley bus
excursion to the trolleybus plant
TrolZa continues to develop and modernize its products. The same "megacities" are issued since 2006, but they are constantly being modernized. Now, for example, they began to produce models with an autonomous course of 20 kilometers. The plant also produces products for export: to the countries of the former USSR, now the first batch is delivered to Argentina.

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